I replied to this on twitter but will do so again here for the opportunity to give a more in depth answer.
I agree with your suggestion for which themes they should go in. Ace is already available in Heavy metal as well as Sons of the Tempest thanks to Caine0 and the fact remains that the bond is what makes that jack shine.
Brickhouse could work with a number of casters, starting with Kraye & Haley2 as you suggest but also Jakes2 (sprint and escort giving somewhat comparable mobility) but with positive charge to help up the damage and accuracy. Nemo2 has a useful toolkit for him as failsafe keeps force lock working and energiser allows for a minor reposition to engage things with force lock. Stryker3 could have some potential with iron aggression for upping the chance of that crit-smite and escort again give him a much needed speed boost.
Dynamo works well with the caster you mentioned (Sloan, Kraye & Haley2) but I also like the idea of him with Caine3 (not only for the feat but also because locomotion can drag him back that crucial inch or two to safety) and any of the snipe casters offer some synergy with him.
Gallant, Jakes1 & Haley3 is a mean, mean combo and I like it! I have also run Gallant (even after themes came out) with Jakes2 for the not quite so impressive DEF skew granted by Bullet dodger. DEF 15 with dodge makes gallant a very difficult to deal with heavy and this is made much, much more impactful by sacred ward. Another reason I like Gallant with Jakes2 is accumulator, with her low focus pool, the desire to cast positive charge and pretty poor personal stats, every extra focus you can squeeze out helps. Gallant is also pretty awesome with any of the Nemos and Darius. Jack hammer works rather well with gallant and its sword being magical fills a hole in Darius' toolkit.
Rowdy is quite a well rounded package, he'll work nicely with any of our casters but I think the two that stand out the most are Kraye and Jakes2, for similar reasons, mobility and focus efficiency.
Thorn, although I sort of agree it's a less happy fit into other themes I'm not sure I agree that Thorn anything like as obnoxious without the bond. Casters that would love to take him though include the Nemos (all of them), Stryker2 and of course Kraye.
Thunderhead and Triumph are already covered.
This does lead to a couple of other discussion points though. Are our character jacks worth taking? Do any of them need a CiD style overhaul?