Carving it in to an aluminum pie pan with an Exacto knife is about your best option.
Depending on what your possible hanging/mounting positions are in relation to the projection surface, you might try the old lens-less projection. Take a fresnel and pull the lens. Put the cut-out anywhere in front of the open face. The image will be sharp, no focus needed. It's basically a poor man's Linnenbach (spelling??) Linnebach projector. As long as the cut-out is parallel to the projection surface, there is no keystone effect. Can be effective at a very short throw distance. You will have spill to deal with, but a bit of black wrap can cure that. I have never tried a par-nel or S4-PAR for this but they might work. This may not work for your situation, but it is a quick and dirty solution to a simple pattern projection.
Since you said the magic "other light" you've opened to door to the Selecon Pacific ( http://www.controlbooth.com/forums/lighting-electrics/22978-selecon-pacific-gobo-options.html ) or various LED profile spots (ERS s) ( http://www.controlbooth.com/forums/lighting-electrics/30020-transparency-gobos-etc-s4-led-lekos.html ) that can use transparencies printed on an inkjet printer.How would one go about using a S4 or other light ...
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