Glad to hear I'm not the only one. All your techniques mirror mine, Hub. I recently tried the loosening of the rear tank bracket and found it helped a lot but it does not eliminate the fuss I must go through with the front bolts.
This is the first time installing the tank with my home made mudflap bracket on. I knew it was always a hassle but with that new bracket in there, I was worried that might be bumping the tank. It actually feels like contact with rubber, not metal to metal. It is awful snug against something on the RH rear corner of the tank.
It was getting dark last night but I see there is paint rubbed off the underside of the tank there. Also, that home made mudflap bracket has the rib facing up instead of down like the OEM. I have the rear brake light sensor clip shimmed so as to not contact the ribs but that also brings it 1/16" closer to the tank. I think the rubberized clip that holds the harness has always rubbed and now it is rubbing a bit harder.
I'm going to have a closer look at it and possibly rout that harness under the mudflap bracket instead of over. If that frees it up, that solves the mystery after the fuel tank has been off six or seven times now. You could do the same thing with the OEM mudflap bracket. Perhaps use a longer bolt on the RH side and then use a nut to attach the clip to the underside of the frame tab...or just zip tie the wire to the mudflap bracket instead.
'08 MIDNIGHT SAPPHIRE BLUE Now Deceased