I can't seem to figure this out. Sounds like it comes from the Front Passenger side.

Under moderate heavy braking, when I push the pedal, I hear this nice "Clunk" sound. As I let off the pedal, I get 2 or 3 nice grinding/crunching sounds.

I looked all over the place. Thought maybe my under brace was loose and it wasn't.

Caliper is on tight, no play in the rotor or anything.

I wiggled all the front suspension bits to see if something was odd there but I can't seem to find anything.

no rubbing or anything with the wheel on or off.

I checked all the plastic wheel well covers as well and they are all solid.

My front brake pads and almost bad new (replaced in May). Braking performance does not seem compromised.

any ideas?

 

Could be a rock jammed in between your brake? I just had this same sound on my truck. Found a rock the size of Utah

 

like between the caliper and the rotor?

I looked around in there with a flashlight and didn't see anything. I think it something was jammed like that there would be a scratching/rubbing sound when the wheel is just free spinning.

 

actually, it was hardly even making any noise for the first couple days! just a squeal every time I applied some pressure.
I'd say if you have the time and resources, I'd take of the tire and do a thorough inspection. Never know what you'll find...

 

I already did that...

 

its your brake discs check the back of them you will find their the problem