I think this contact surface is awfully sharp. I've set the holes up like joes and many others. Also tried various spacings all ride on bearing edge. I mocked one up at .625 in and the bearing rides flat but nuts hit top and won't nest. is everyone elses like this. here are two pics and you can see thanks joe.

I used longer bolts with washers stacked then a spacer nut. Works just fine. It looks like you are using the bearing height used for the 3/4" pipe, and not the right stack for the 1" pipe. There are two different spacer lengths. due to two different pipe diameters.