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I think I've given it a little extra, but at this point I think I've re-tightened every nut and bolt on the front end

Not the front end pop/clunk, but in full lock the steering wheel does make a slight knocking sound which sounds like it's coming from the drivers side. I had someone do it while I was underneath and it sounds like it's near the pitman arm area. The main pop clunk on the passenger front corner...

Were you able to figure this one out for your setup? I installed the JKS 3.5 lift and 35's a couple of months back and I'm having the same issue. I've retightened everything and nothing seems to fix that pop/clunk in the passenger front. I can re-create it with no problem by pulling in and out...

Looks great! I just got a 2025 Nighthawk and I'm looking at a small lift and 35's but went down a rabbit hole of needing everyone saying that if it's not a Rubicon or Mojave you need to re-gear to put 35's. Do you have any concerns with the 3.73 or any plans to re-gear to 4.10?