Great Points! I will look closer at the clearances.. Last time I went down the path of isolating that crash - I wound up focusing on the lock ring which locks rotor to the hub. Then the bike is on the ground and you pull the brake lever hard and move the wheel there is slight movement. movement I compared to a buddies bike and it looked similar movement so I stopped there. I am thinking of trying a different pad, (I found a thread where something had kinda similar but they had lower grade resin pads). I will setup a better camera angle and run the wheel like you suggested on a stand and post as well as rocking the front wheel while on the ground with lever pulled tight to show .
Thank You