No, for the initial visa (fiancé or spousal) you only need the biometrics photo page of his passport. Nothing more.
For the cover letter, I would rewrite it, or at least update it with the current date, since it should be dated as close to the application date as possible.
I would also have him mention the refusal and the reason for marrying in the US... since he will need to put that in the relationship paragraph anyway.
Also, since you are now applying for a spousal visa, the letter should be adjusted to refer to you as his wife, not fiancé, and give the date and location of the wedding instead of the UK wedding plans.
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