Done. There is not a lot of "real estate" on the attachment point. Anything bigger than a 1/8 inch rivet will likely compromise strength. I shaped a crown using 0.03 inch aluminum and attached it using Gorilla Glue and 1/8 inch pop rivets.
Below are photos of the headlight attachment point: prepped and drilled-first picture; the crown installed-third picture; the speed nut in place and headlight ready to be reinstalled-second picture.
Also, I used anti-seize on the allen bolts in order to minimize any binding / torquing of the fasteners in the event I have to remove the headlight covers in the future.
Whoever designed the headlight covers gave securing them to the clam about 15 seconds thought. Those ABS plastic towers are a pathetic weak point. I've had to remove the headlight covers for one reason or another every year for the last 5 and have attempted to repair them with little success (including Gorilla tape to try and stiffen the towers and epoxying the top of the tower where the clip nut thingy attaches). I'm removing the clam to replace the radiator and *surprise* both fasteners broke off again.
I'm going to try the fixes in this post and hope for better results.
2006 Ardent Red Elise
Touring, Star Shield, hard top, remote V1 display and bracket, sun visor delete, micro mirror, shifter fix, Stage II exhaust, de-snorkeled, ITG air filter, Nautilus horn, black LSS wheels, ARP wheel studs, upgraded oil line fittings, ProAlloy radiator, s.s.brake lines, BOE Race Links, Innovative rear motor mount, plastic grills out, all aluminum mesh, Total Oil Control Wet Sump V1.1, s.s. caliper pistons, BWR sway bar, Penske NA coilovers.