The former king has a very big body, so he can withstand the crown's weight even if it seems literally impossible to that of an average human. Zilch's body is not exactly "thin", it's more of fit and athletic but his tallness (being over 7 foot tall) makes it a bit hard to put the heavy crown over without using abilities, but not impossible. He doesn't want to get overly suspicious among the public, so he decided that he told the crown designers to create anew.
p.s.: It's funny that the onion alien soldiers barely get any armour because that's a whole ass empire you know. Either that it would be too hard to animate a family friendly cartoon or that the former emperor doesn't want to have them.
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