OK, I see what you mean, the two images could basically be different sizes because they are on different film bases.
I use FP4+ film (in 4x5 and 8x10 formats) for my unsharp masks and get good results. I used Arista Ortho for just about all my other masks but never quite got the resuts I wanted for unsharp masks. If you place the FP4 film at the bottom and place your negative, emulsion up, you will get a good mask. Both films emulsion up or both films emulsion down ~ let the base of the negative film be the spacer (vs. adding a spacer).
adelorenzo,
I think Prof Pixel suggested that maybe your film isn't on a base (like glass) that is immune to size changes after processing, because you got it wet and dried it. I'm guessing that since you are working with 4x5 film, dimensional stability isn't going to be as big a problem (say as if you were working on 11x14 film).
I'm not sure how to tell if an unsharp mask is in register... I'd rather have it punched so there's no question.
A pin system doesn't have to cost money. Tape tabs with punched holes and a pair of register pins can be all you need.
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