Today I took off the rotors to try and see if I could notice any unit bearing issues. Everything seems in better order than I thought.

I did find my passenger knuckle has a small brake pad groove wearing on the top inner side of the knuckle. Can this be lightly sanded down?

I believe this maybe causing the noise as I've replaced my front pads and haven't heard this noise again. Shame though the other Napa pads were still in very good shape but they were crap.