Took apart the rhs four times so far. Finally put the cupped washer on correctly (note to self...write down sequence or note it in the manual on the picture!) AND tightened down the cartridge retaining nut with a pipe wrench through the spring. Seems the clunks were from the cartridge not being held to the bottom...about 2mm off. And the cupped washer that sits on the neck of the strut was below the bearing retainer rather than above. Confirmed when I went to the left side.

And I used a cutdown bump stop. The bottom inch or so of the stock volvo bumpstop...heck, can't hurt. It's very flexible, the bottom inch or so...doesn't get hard/solid until farther up. No bumps, clunks, etc.

I think I'll add the Bilstein spanner wrench to my collection if I can find one. I got the IPD top wrench for the jesus nut (it adds 6" or so to the torque wrench so you have to use like 75ft lbs on the torque wrench to get 118 at the nut. The 7mm allen wrench I used to hold the strut rod twisted out the internal socket on the driver's side at about 110ft-lbs...I didn't get to hear the click but it was very tight. If I have to remove the driver's side strut I'll probably have to crack the nut or jam a 7.5mm wrench or english equivalent and swage the socket tighter.