tim48v,
I know what you're going through. Good luck in your quest.
I once cut a 4x5 negative carrier to fit "real" 4x5 film because I wanted to have the black border but not have the film fall out.
I thought I had found the specification and worked from it, but in my notes, I see I actually measured a piece of film (the film I measured is taped to my notes).
I measured a 4x5 sheet of TMY-2 as 3.918 x 4.925, which was short about 5/64" on each dimension (close to 21/256" on the 4 inch dimension and 19/256" on the 5 inch dimension)... Shy on each dimension from actually being 4 x 5 inches.
So what you have to do is consider the +/- tolerance for trimming, because you want your system to work within these tolerance.
And you should consider any dimensional stability, shrinkage due to temperature, age, humidity and processing...What can that amount to? 0.5%?
I had to deal with the smallest expected because I didn't want the film to fall through... But you have to account for the biggest expected dimension.