Here is your closeup on the welds. I cannot take credit though. My neighbor is taking welding classes, so I just tacked everything up and he finished it up much better than I can right now. I am still using flux core so it's ugly, but I have my gas setup on order, then we'll see where I am at.

As for the pipe size, it is 1 inch and actually looks bigger and more substantial in person. That being said, I may do it again with 1.5-2" pipe. I just don't like the big "nerf bar" look. I think it distracts too much from the truck. I am still not too keen on the upper bar as it covers the grill. I also have to do the back guard.