I found this picture of my bike before the tear down. I rode that fork brace for about 10years with numerous hard stops and never had a problem seems like it should have bottomed out. I'm curious of what the travel should be.
Woah, that is very little travel if your fender never hit the brace... Were the forks in working order? That is scary, something must have been done to them.
It's scary because when you ride around turns, for example, the fork is supposed to compress (inertia) and it will absorb imperfections/bumps on the road so that the tire stays in contact. Losing contact means losing grip means being part of the scenery real quick. In other words, messing with the suspension can be dangerous. If the springs are maxed out or rebound too fast/too slow it can be bad.
Bottom line is, did you notice anything strange when you rebuilt these forks? What happens when you stand on the bike, grab the front brake and push real hard up/down on the bars? There should be a fair amount of movement and it should not bounce right back nor come back up slowly.
Your bike looks good now, nice work!