Achieving a clean, professional look when installing a roll bar through plastic side panels:

The object is to accurately cut a hole in the plastic side panel leaving an even gap around the roll bar as it passes through the plastic side panel for a professional-looking installation.

Step 1:  Measure the length and diameter of the side bar on the roll bar and purchase a piece of PVC pipe in the same diameter that will pass through the plastic panels.  Cut the PVC pipe to match the length of the side bar.

Step 2:  Install the roll bar following the roll bar installation instructions. When it's time to install the side bar through the plastic side panal, remove one of the side bars. Make sure the rest of the roll bar mounting points are bolted in position. Using the PVC pipe, insert it into the location of the side bar that has been removed. Shorten the PVC pipe just enough to allow re-installation of the plastic side panel. Once the side panel is in place, slide the PVC pipe down to where it contacts the plastic panel. Trace a line around the PVC on the panel where you need to cut out. Next, remove the PVC pipe and cut out the hole in the plastic panel. For 1-3/4" tubing, use a 2" hole saw because this leaves a 1/8" gap around the bar to eliminate squeaking noises. When drilling the hole, try to drill it out at the same angle the side bar will be. Take a small file or sand paper to remove any rough edges left by the hole saw.

Step 3:  Now the fun part. Loosen the side panel enough to slide the side bar through the hole in the plastic. You should be able to work both into place so you can bolt the side bar in and put the plastic in place at the same time. On a Mustang, it helps to have one person reaching through from the trunk area to help out. If you are patient enough, don't rush the job and use PVC pipe that fits snugly into the roll bar, the result should be professional looking installation.

This process requires partially removing the roll bar a few times. Make sure that at each step the roll bar is tightend down so alignment is always correct. Most importantly, make sure that all bolts are tightened to spec. when you are done. Good Luck.