To answer the actual original question,
“what does one do with the oem projector headlight bulb dust cover to clear or fit over LED replacement bulbs?”
- as a couple members stated, you can:
A) buy a set of deeper replacement dust covers
(the only vendor offering replacement covers that I am aware of is referenced in a previous post in this thread, and those come pre drilled with rubber grommets, ready for HID bulb kit installation, but they may offer the deeper covers not drilled - I don’t know for sure), or,
B) you can use a heat gun to “massage” your existing dust covers to fit over the bulb base, or
C) you can replace your bulbs with bulbs that will fit under the factory dust covers
D) you can run without dust covers - not recommended in my humble opinion, but you could......
I know the Katanas/Supernovas and Max5 LEDs fit under the dust covers because I have them in my oem projector headlights, and there are a handful of other LED bulbs that forum members have confirmed fit as well - there are several threads in this forum you can search through and read at your leisure