I took off the gear basket, to clean out leaves of previous owner, and it looks better, but the front baffle thing rattles like hell at 40 mph, is there a trick to get it to not flap around or should I just put the gear basket back?

It is likely because of one or more of these things:

Torx tight?
Rubber strip on bottom of air dam worn, missing?
Foam washers worn out where torx go between basket Air dam?

Pretty easy to improve issues with homemade options to stop the shacking and rubbing. Also could just totally remove. It does not help with aerodynamics, but then you loose the looks and place to put stickers.

I believe the rubber strip on bottom of dam is missing, as there's a gap between it and the roof, hmmm...