Hi Mick, thank you for the detailed post and suggestions, appreciate it!
Personally I want to avoid mounting panniers again to try keep it as light as possible. I like the size of the 4L Ortliebs and do not really want to go bigger than that. I have the ability to carry my gear on the back, which is not very much anyway.
Here is a pic of my Nomad from yesterday on the Spoleto to Terni trail in Umbria, Italy. On the back I have 2x 20L Ortliebs and I can strap my tent on the rack if I need to, however, as this was a day trip, 1 bag was plenty.
I do not know how much the Thorn rack weighs, I do not own one. But that is smaller if you stay with conventional panniers.
With regular panniers, I use a different rack made by Axiom. The rack is aluminum and does not weigh very much.
I wanted my panniers mounted up a bit higher so I tried this rack. And after I installed it, I did not like how it looked like it could be damaged in a crash, so I added an additional aluminum bar bracket to connect to the other side of the fork upper mounting to make sure that the rack could not easily bend if I had a crash.
In the photo I also added some plastic hose to protect the paint from chaffing. The pannier brackets attach several inches above where the fork mounting is, which is the main reason I picked this rack. Bottom of front pannier is almost as high as the rear panniers.
On a different bike with the front panniers hanging down really low, I scrapped a curb with my pannier once. Fortunately I did not crash, but that made me nervous about panniers being that low.
Top bar is not quite horizontal, but it is close enough that it does not bother me.
The extra aluminum bar brackets that I added are 3/4 X 1/8 inch, and i sprayed them black.
I have Ortlieb Frontrollers and Backrollers in the photos.
I had a Surly rack and after two tours, I donated it to charity and bought different front racks. (I have three touring bikes, I have three different front racks for them.)
I am looking forward to when Dan has a photo of his mounting system. I suspect it is something similar to something that I have considered doing with some aluminum bar instead of the stainless bracket that he used. I was thinking using an aluminum bar (3/4 X 1/8 inch) and drill two holes, one hole for upper fork rack mount and one hole for lower rack or fender mount on the fork. Then add two or three holes in it for a cargo cage. Might be able to use the uppermost rack mounting bolt to also hold the cargo cage. Would likely have to bend it slightly so it does not rub on the fork paint.