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I would say to start out with, get the 1.5" and 2" dies. That seems to be the most used sizes, then he can get more later as he finds the need /forums/images/graemlins/thumb.gif
I haven't heard of anyone using 1.5" for full-size cages (it always seems to be either 2" or 1.75")....the 1.5" might be good for bumpers and rock sliders, and the 1" is good for the gussets and grab handles....
Concur with the above. Mostly yall will use the 2 and the 1.5". Get the 1" for doing fun stuff. Others will mostly likely be needed for really special projects but by then you will know which one.
I currently do nearly all of my bending with the 1.5" die and just run a heavy wall tube. Most of the people I build for are happy with using 2" in runs and 1.5 for bend areas. I've got a guy who is looking at some sliders for his burban and he will be completely happy with the 2" runner and 1.5" hoop.
One idea most people don't think of is the square dies. I've got a 1" Square die and use that to build roof racks.
I've got a 2" and 1.5". IMO this is my size breakdown: 2" for full size cages, 1.75 for smaller or lighter trucks, 1.5 for bumpers and sliders. 1 5/8 for high speed applications (heavier wall tubing).