Sweeeeeet looking project. I love the Tomaselli style headlight brackets. You mentioned needing to get them on before tightening the forks? Another option, although not as good as putting them on the way you did it, is to slice the rubber sleeve so you can get it onto the fork tubes.
Of course to get the original ears off, you need to lower the fork tubes anyhow, but just saying - it is a way around it.
Can't wait to see more pics. The added metal to the frame to match the seat looks awesome. What are you doing for rear signals (what many of us have used those leftover holes in the frame for after removing the rear fender/grab bar etc.)?