please explain... not trying to beat a dead horse .....newbie here lol. What was your experience with procomp shocks and/or downey HD torsions?
First I'll say that I have run a 4runner with a 22re + stock suspension and no added front weight with: stock bars, 25mm and 26mm bars. On the trail the stock bars rule and are well suited for a daily driver. The 25mm bars improve the street handeling and high speed control without making the daily ride to ruff. However due to the stiff spring rate they will lose about 2" of compression on the trail, especially when the front suspension is unloaded. They will compress close to the stock bars when the suspension is loaded. The 26mm bars are just not pratical on the street or the trail. I would extrapolate that a 3vze truck with an added bumper/winch would best benefit from the 25mm bars. The 26mm bars could be tried, but probably would still be on the stiff/ruff side. If there is a TON of weight on the front of the truck and you do high speed trails, then the 26mm bars are for you but thats the only practical implementation of these bars. I run angled upper arms on my truck and have used stock bars, 25mm and now 23.5mm bars. Even with the extra arch leverage of the arms on the 25mm bars, there was a loss of wheel travel ease.
A huge misconception many people have is that larger torsion bars are some form of "upgrade" for the '86-'95 trucks/4runners. The main issue with larger bars is the HUGE increase in spring rate. 25mm bars have anywhere from 55-65% increased spring rate and the 26mm bars have over an 80% increase. Keep in mind that the diameter of the bar is not the only factor in its' spring rate. The alloy of the metal also effects the spring rate. This is to properly set ride hight with proper spring pre-load, which cannot be done just by bar size. A prime example is the stock bars, which are all 22.8mm but have increased spring rates to account for a 3vze motor, 4runner, 2wd or 4wd and yet they all have the same pre-load and ride hight. Also depending on suspension design, torsion bars don't just twist in a straight line, angled arms will not only twist but arch the bars.
The stock torsion bars are 22.8mm in size, aftermarket bars run 26mm, 25mm, 24mm and 23.5mm. 24mm bars seem to have fallen off the market and only Old Man Emu makes the 23.5mm bars. 25mm is the most common now in brands such as Rancho or Sway-Away. Downey's are only available in 26mm's and I think Rancho has a 26mm bar.
Don't get me wrong, I think going with a larger bar is a good "overall" improvement but it hurts upward wheel travel. If you run stock arms, the 23.5mm OME bars should be the main bars to consider but stay far far away from any 26mm bars.