Welds look great, the bar fit perfectly on all the mounting locations except the passenger floorboard. That said, that mount was only 1/4" off the floorboard and the bolt sucked it down perfectly flush when tightened. Plus my supra has been through more stress/strain than 99% of the mk3's, so I honestly expected most of the mounts to be slightly off.
The side flanges are made with a small gap (~3/8") to accomidate the interior panels (as well as the stock seatbelt if need be). Since my car is gutted, I used some washers I had lying around the shop to mock it up. I now have a metal plate waiting to go in to act as a better spacer than the washers -- and whenever I get time to install it, I'll try to take some chassis deflection measurements too.
Edit: damn, the size requirement is smaller now? I thought it used to be 80k?