Your own explanation will be (partly) correct: different polarizing foil.
Partly, because the same less effective foil could also be used in circular polarizers, the better also in linear polarizers.
How did you cross the circular polarizers?
With two of them pointing the same way, with the polarizing bit towards the light, the light hitting the second one is not polarized, and cannot be blocked 100% by it.
With both of them pointing the other way, same impossibility to block all of the light.
Have one reversed so that the quarter wave plates are on the inside of the 'sandwich' would have little effect too.
Have one reversed so that the quarter wave plates are on the outsides of the 'sandwich' would work. But how do you mount them like that?
I think that all the light coming through the first polarizer is totally polarized. The second one mounted in the usual forward way blocks that polarized light when turned to 90 degrees. Theory may not be right but it sure works.
But this was as much a curiosity to me as anything else. When I figured out what was going on, I thought that other APUGgers might be interested to know that a CP and an LP might behave differently in a worst-case situation.
And stacking two polarizers, with a linear one in front, will yield only a continously variable ND effect.
I thought this was interesting.
No doubt others already know this.
And a LP and LP. Or a CP and a CP.
Just so this point is clear: it does not depend on being either a linear or circular polarizer. It's not a linear vs circular thing, but a good vs less good thing.
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