OK, so I took it all apart again last night and did the following:
Added some pre-load to the driver's side spring
Lowered both sides to see if the end-link was hitting the control arm (whatever it's called)
Reduced negative camber to ~2.0*
Nothing. If anything it's worse today. I took some audio on the way to work.
The end-link doesn't appear to be hitting the arm, but it's pretty close. No evidence of rubbing or rattling. I hit everything with a rubber mallet last night and everything seems solid with no rattling or odd noises.
Blown shock?
Edit: I also did look at the lug studs and they are fully seated. I also counted the old studs in the trash - all accounted for. The noise is beyond a bolt rattling - the whole assembly seems to be rattling around.