mylar is MOST DEFINITELY conductive. big time :-) but not a big deal. Just use a board where the holes are the same size as the LED HEAD. mylar the front and push the LED's i n from behind. Now no contact between the mylar and the led posts. would take a hell of a lot of soldering though. Wow :-)
aim might be less a problem than you think. I am thinking go with projector head lamps (fewer led's so you would have to use a QUAD arrangement of headlamps) and simply "adjust" the projector till you get the beam spread you want. (in theory)
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