Getting back to your original problem, are you going to try and calm the noise down by fitting a thin rubber washer between the top of the damper unit and where the rod that holds the spring returns to,
There looked to be a top out bumper on the other leg (the half rounded rubber thing) but it sounds like the top of the cartridge is being slapped by the rod that supports the spring returning towards the carrtridge..
....very hard not being there in person perhaps there is a thin washer there already ?
Regard the lelt leg one of the spacers has what looks like a seal on it to stop oil in the bottom of the leg traveling up in the fork tube so it stays below and is used inbetween the inner and outer legs to lubricate........if so you may have to ignore my ealier statement about springs drop in 1st then spacers.it's normally the way, but if it has a wipper type /seal on it it needs to goback the way it came if you can remember.............perhaps you video'd the forks as you took them apart.