Nice work hitting the 1000 it's been a long time coming!
On the stud for the tensioner , maybe the front cover can have a hole machined into it to allow the stud to be removed with the cover in place,then a screw in plug added for running. This of course is a mod down the road.
Believe it or not,Ducati motor cycles use a swinging idler pulley to tension the cam drive belts,they are all stud mounted in aluminum.
I like studs in every position in aluminum if the fastener has to be removed in service.
I rewire airplanes,the area looks a lot like yours no matter how much I try to keep it cleaned up.lol