I just bought a pair of the Spotlite Kustoms aluminum valve covers (the ones that look like the OEM steel covers but with fins).

Didn't take long to realize the stud holes are too small for the OEM grommets. The lower portion of the grommet that sits inside the stud hole is about .100" larger than the hole. Figured I could just shave that part off and try it, but even after that the remaining portion of the grommet is still too fat to seat correctly in the recessed area around the stud hole.

Wondering if anyone else has run into this, and what you did to make it work.

The correct grommets either should have been included or offered for an additional charge. When you communicate with Spotlite Kustoms, let them know that you will post the outcome on this forum. Unfortunately, these days, there are businesses out there that just don't care. I guess it comes down to how badly you want those valve covers and what measures you're willing to take to make it right. Whenever I can, I use Amex for purchases. Amex will remove the charge whenever there's a problem with a product and the seller is uncooperative. eBay, Amazon, and PayPal, possibly others, offer some consumer protection in such cases. 

You might get by with using RTV and the correct size washers. 

Agreed, it would've been nice if the correct grommets came with the covers, especially if they're different from the OEM. The response from Spotlite was that there are two different types of grommets, and I apparently need the "other" type. They don't happen to sell either type.
Like most Y-block guys, I've got tons of these grommets lying around. They're all the same, at least the ones I have. The only difference I've noticed is some seem to have a thin layer of rubber over the washer, and others have the top of the washer exposed.
Out of curiosity I went to the Concours Parts site and sure enough, they list different grommets, one for steel valve covers and one for aluminum. That was news to me. I've always used whatever came in the gasket kit and they've worked on both types of valve covers. So for kicks I ordered 4 of each. Once they come in we'll see if any of them fit. 
The whole thing just seems kind of odd. I've seen nothing but positive reviews for these valve covers, and no mention of "make sure you get grommet X". 

Looking at the valve covers, it looks like the space for the flat washers is too small besides the problem with the grommets.
Like the poster, I never knew there were two sizes.  I have the TBird covers on both of my cars and the grommets I have (and have a lot of extras) seem all the same size,.  They also fit the valley cover.  I have a couple of tin sets around so I will try them on those.

CASCO  only lists one grommet, but Hill's list two sizes, one for steel and the other for aluminum .  In t Hill's and Concours , , the listing for the steel ones are also for the valley cover while the listing for the aluminum ones are for the rocker covers only. 







54 Victoria 312;  48 Ford Conv 302, 56 Bird 312
Forever Ford
Midland Park, NJ

I guess I better check to see what size I'll need for my Ace valley cover before I install it. 

Regardless of what valley cover is used, make sure the grommet does not make the front valley cover bolt sit so high that the intake manifold sits on the bolt head.  Bad result is a manifold or water leak.  Worst result if breaking off the front ears of the intake manifold.  Check by setting the intake on the heads without a gasket and see is a feeler gauge or a thin piece of cardboard will pass between the bolt head and the manifold.

John - "The Hoosier Hurricane"