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Originally Posted by CambsIan
Can anyone tell me if all the 5x4 DDS's are the same size ?
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Yes, all 5x4" double dark slides are the same size, dimensions standardised in the US before 1914. Those intended for glass plates are thicker but the emulsion plane is in the same position, with respect to the darkslide flange. Adapters were available to put sheetfilm into darkslides intended for glass.
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P.S will buy a professionally made "hole" if the project goes ahead
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You are wise to get a good hole, perhaps etched from thin steel, because that defines the image quality. Some textbooks suggest piercing cooking foil - bad idea! You could try melting a hole with a hot needle in a black polyethylene bag such as used for packing photographic paper.
I remember, now - I made pinhole cameras for the solar eclipse in the late 1990s. But the best one had a 10mm diameter hole and a 1 dioptre spectacle lens. The box was 1 metre long, of course, and had a matte drafting foil 'screen'. You could see the furry bits around the moon's shadow.