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I think you could hollow out a space with a sharp knife and then fill it with bondo. Drill the mounting holes in the bondo, a bit on small side, then thread in your attachment screws.
I copied your design to a considerable extent making a lower grill block for my Insight Gen 1. I use polyurethane sheet over the large opening surface to keep the foam out of the grill and to provide a release agent. Only proble I ran into was that the foam would not cure in the deep parts, so I had to take it out and slice off the back part to get it open to cure. Worked out ok. BTW, brake cleaner will disolve the foam and aid cleanup.
I have my first coat of bondo on the outside surface. Need to do some sanding and smootinging. I plan to attach mine with two very small self threading screws near the ends. Since the block is deeply recessed in the Insight, I think that is all I am going to need. My block has taken a slight outward bow at the ends, so small screws near the ends are going to be perfect - I THINK.
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