Deck lid rattles bigtime

Yep, I thought about the expansion issue, but I figured that I could go easy on the foam and it shouldn't be a problem. It's not what I would consider a confined space - the foam can expand horizontally. I wasn't aware of the "low expansion" version, I'll have to check on that.

The deck lid is painted and is on Aaron's daily driver, so the removal, drilling, waiting for cure time, and all that is not really an option. The fix needs to be done with the lid in place and ready to go in a day's time. I certainly don't want to do any drilling and plugging.

The latch is not the problem. We have already adjusted it as much as we can, and the seal is in good shape - it's only four years old. The rattling is clearly caused by the flimsy outer skin contacting the inner skin and its stamped subframe ribbing. You can tap on the deck lid's surface with your finger and reproduce the rattle.

The panel adhesive is a potential option, but it would have to be thick enough not to run, and it should be able to fill a slight gap between the two skins, similar to how it was originally done with the body filler putty. Also, bear in mind that there will be little control over where the product is applied, since I will be blindly putting it into place between the two skins.

Good ideas, though. Keep 'em comin'.