Horatio
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Mat board has been used for custom sized or improvised negative carriers approximately forever. A layer of packing tape, carefully applied to be wrinkle free, will help avoid negative scratching. Strips of straight tape can act as rails to guide the negative strip, to ease getting the actual image area aligned with the mask opening.
Another option is glass -- Anti Newton Ring (or the anti-glare glass from a better picture frame, much cheaper but less durable than acid-etched ANR) is preferred for the upper side, which contacts the film base, and strips of tape can serve as both negative guides (between the glass layers) and frame mask (bottom side of the lower glass, so it doesn't interfere with negative positioning. Once again, this is great for sizes that are hard to find -- 6.5x9 sheet film, for instance -- or oddball film sizes, or those with offset frames (828, 126, 110, Minolta 16, etc.)
There is also some advantage to using glass on the top side only. ANR or partially etched glass is best.
You also might be able to make use of the Beseler carriers.
Mat board has been used for custom sized or improvised negative carriers approximately forever. A layer of packing tape, carefully applied to be wrinkle free, will help avoid negative scratching. Strips of straight tape can act as rails to guide the negative strip, to ease getting the actual image area aligned with the mask opening.
Another option is glass -- Anti Newton Ring (or the anti-glare glass from a better picture frame, much cheaper but less durable than acid-etched ANR) is preferred for the upper side, which contacts the film base, and strips of tape can serve as both negative guides (between the glass layers) and frame mask (bottom side of the lower glass, so it doesn't interfere with negative positioning. Once again, this is great for sizes that are hard to find -- 6.5x9 sheet film, for instance -- or oddball film sizes, or those with offset frames (828, 126, 110, Minolta 16, etc.)
A trick with Mat board is to toughen it up with wood hardener or Super Glue, get it to soak in - needs care. I've made my own Aluminium 35mm and glass inserts for Durst enlargers. My personal preference is glass on the bottom and metal frame on top to hold the negative flat, and that also helps eliminate dust issues.
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Back to the OP's question, I've made complete negative carriers from Aluminium and wood in the past and it's quite easy.
Ian
I'd recommend trying to make a glass carrier. The thing with 35mm and 6x6 is that my tests showed curve of the film is opposite the curvature of the lens field (at high magnification; 16x20 etc.). For 5x7 and smaller, probably does not make any difference, though. So anything you can come up with should work.
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