In Reply to: Ditto & a question posted by RichC on June 14, 1999 at 06:38:51:
You will need to open it up over 1/4". It really does look like a lot of metal, but it isn't bad. I took a compass and drew a 1 5/8" dia circle on a piece of clear acetate and used it as a template. I could see through it to line it up with the other hole. Use the drum sander with the dremel tool. Get a few sander bands as you will need a few. Go slow it will take a while. Take about 1/32' off at a time trying to keep the hole round. Don't worry, it doesn't have to be perfect! The grommet will cover about 1/8" of imperfection. Be sure to fit test the grommet as you get to the final dimension. When the grommet fits OK stop and test fit the chrome piece into the grommet. Then you will see if you have to take out a bit more. Remember - this takes time - BE PATIENT - GO SLOW!
Also - you should be able to snake your Dremel tool in from the inside of the trunk lid. Don't work from the outside. One slip and Black Manx's coat will be missing a few hairs! If you work from the inside and be careful with the sander drum, you won't have any mishaps as it gives you a built in guard.
As for the rust problem, make sure that you de-burr and paint the newly exposed edge. Another good idea would be to coat the inside groove of the grommet with a clear silicone type grease. This will seal it and keep any air or water from getting to the metal edge.
Good luck to all - jd