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I am using 1.75" x 0.120 wall DOM. For smaller rigs, some people use 1.5" or 1.625". Some people go bigger, like 2". I think for a fullsize truck, 1.75" or 2" are the best options.
can the large tube bender at like Harbor Freight bend the tubing or would I need someting else.
HF sells a lot of pipe benders... they will kink/screw up tube. Not sure if HF sells a "real" tube bender now or not. Your best bet is to go with an established bender maker, like Pro Tools. I have a 105HD.
As far as cage design goes, do a search here on ck5 and on pirate4x4.com... its been covered many times. In general, triangles are your friend as is attaching the cage to as many points on the body and/or frame as possible.
If you have more specific questions not answered by searches, post 'em up...