I used 1/2" size schedule 40 "handrail" pipe, its the same HREW for plumbing without the threads or the black anti-rust laquer. its outside diameter is 1 1/8" inside diameter is actually 5/8-3/4" (useful if you need to slug a joint) I used this for almost everything on my ride, but I do have to 1 1/4" x 3/16" main tubes for the bottom of my ride. I am replacing the main hoop with 1 1/4ID HREW as it bent when I rolled it, but it was not triangulated. something like 3/4" or 1" HREW/handrail schedule 40 is super strong, and thick, thickness has been 3/16" for the 1/2 and 1" I rolled mine doing about 25mph, and everything triangulated was fine. good luck with your build
if you have to weld pipe end to end you should do what i call slug it. i use a rod or pipe that fits snug inside the pipe i am working with and use that to keep the pipe straight as well as add some extra integrity to the joint. the first pipe is welded to the slug and the second is welded to the weld or the slug> you can fill the gap with weld and grind it smooth.this works very well and is super strong.
if you are welding side to end and have no structural requirement for the part you can flatten the tube and weld it that way. many cheap carts are that way and its ok as long as it is welded well and load orientation is kept in mind so the length of the weld is kept vertical to the load.