Many thanks for your thoughts guys!
I'd not noticed the aperture on the test images on the PLM page & my test shots were at either f/11 or f/14. I'll give it another go and close down the aperture... this does make sense as there was definitely a noticeable spot to some of my test shots where I was obviously close to the optimal focus, it just wasn't as defined as I'd hoped for, but I think a smaller aperture would help. I also need to get into the dance studio (which is much bigger than my tiny garage!) and use them in a more realistic setting.
I was thinking that movement of +/- 2" would make a reasonable change the exit light pattern due to the nature of the PLM. If all else fails I'll be making large barn doors!
Just for info... I'm pretty sure that what I'm looking is possible from these sources:
https://www.youtube.com/watch?v=W6bS8tgjSTwhttp://www.peddecordphoto.com/2011/06/01/86-silver-plm/And I'm thinking that angle the PLMs slightly forwards so that the rear edge of the beam is defined and I can burn the front portions in PP.
Thanks again for you help - It's much appreciated!