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Nice!

Black pipe is the way to go. Never PVC, as already stated. The sizing will depend on how long your runs are. Taking into consideration pressure drop the longer it is.

Another vote for a Reznor. Have had one in my shop for about 5yrs. and very happy with it. Installed just like Dan suggested.

You might try over on the http://www.garagejournal.com/ If I remember correctly, there are a couple good threads about the MaxJax.

Always a nice feeling to get a project like this done. Nice.

Weld around the the outside edge of the hole and circle in to the center.

Nice. Good job.