Hey fellaz, I did not update the status of the clunk after the new bracket, but it wasent that.
Good news is I think I've really Isolated the noise this time, it is one of 2 things: the strut mount, or the spring seat.
I thought it was the strut mount for the following reason:
clunk happens when going off small bumps like garage enterance or driveway entrance. Noise is ONLY when car is cold, after driving for 20 minutes or so, it stops, so def heat dependent noise (when heat expands part, noise stops)
I isolated the noise because I waited for the car to be cold, opened the hood, pushed on the front bumper to make the car bounce and the clunk comes from the strut towers, it's very distinc and easy to hear. The only part I see is the strut mount, so that was my diagnosis, BUT...
I just contacted a very competent parts guy at a local volvo dealership, he says that the SPRING seats often fail, and that the new fix at volvo is to replace all of the noisy seats with XC90 seats because they are beefier (bulletin from volvo advised them of the fix) and he says that they very rarely change the actuall strut mount, they rarelly fail.
So, you think its the spring seat since they are prone to fail and the sound comes from that region (strut tower) or it might be the strut mount?
I hope its he spring seat cause I can get them for 44$ and the strut mounts are 144$!! yikes!
I've been rolling on KW coiloves, lower and stiffer than stock for 2 summers, so unusual wear is not impossible...