Can you use schedule 40 and schedule 80 together? or are the diameters different? I want to use some schdule 80 threaded nipples but they seem a little loose in the schedule 40 fittings.
For 1" pipe, sched 40 ID is 1.029 while sched 80 ID is 0.936... no wonder you're finding the sched 80 nipples are loose in the sched 40 fittings
Based on these numbers, I'd say it's safe to mix fittings that are based on OD (like elbows, tees, etc) but not fittings that are based on ID like nipples... just my opinion, though.