Okay everyone, I did some more testing and it has just left me with more questions than answers. Without going into all the details I think I can rule out bad film holders as the issue. I also think I can rule out light leaks in the camera causing the issue as well.
My last shoot consisted of HP5 loaded into two different types of film holders (Toyo & Riteway), and while the film edges don't appear fogged at first glance, compared to other negatives I have shot, they are slightly darker. With further inspection, the edges with the notch code are slightly darker on most of the shots (doesn't matter which film holder used). All the film in this "session" was loaded at the same time and developed in the same tank. Why are the rebates of some of the negatives darker than others? Shouldn't they all be the same?
I ended up taking a deep dive into all the 4x5 film I have ever shot. I have walked away with the following conclusions:
1. The problem only exists in my HP5 negatives, but the sample size of Catlabs 80 and FP4 film is comparatively small.
2. About 50% of my HP5 4x5 negatives display fogging and/or elevated base+fog
3. The edge containing the notch code is usually more fogged than other edges
4. The issue has occurred through 3 separate boxes of HP5
5. The issue has occurred through a variety of film holders and is intermittent with the same film holders
Concerning my development routine:
1. I use HC-110 dilution B or film rated iso 400 or higher
2. I only use HC-110 as a "one shot" solution
3. I use Ilford Rapid Fixer 1+4
4. Fixer is periodically replaced
5. Fogging issue is not linked to any changes in my development routine
6. Fogging does not occur with 120 roll film using the same development routine
Concerning my darkroom and film loading routine:
1. Film gets loaded into my developing tanks using a dark bag
2. My dark bag is known to be good. I have developed countless rolls of 120 film using this bag
3. For 4x5 I use a Paterson style tank and SP-445 and both have exhibited the fogging issue. I used a smaller Paterson tank for 120 film and that has never had a problem with light leaks
4. I load my 4x5 film into film holders outside of my changing bag to reduce dust issues and aid in ease of loading
4a. I perform this in my blacked out basement
4b. Only done at night with lights on the flood above turned off as my basement is not perfectly light sealed during the day
4c. All light sources are either turned off or covered
4d. I scan the room each time to check for any light sources after my eyes adjust
After reviewing all of my previously developed film and trying to replicate the issue, I'm looking at my film loading routine. Specially loading my film into the film holders as this occurs outside the dark bag.
Is it possible that there is some source of light that is not visible to the naked eye fogging a faster film (like HP5)? With paper you can get away with your darkroom not being perfectly light sealed, but film is obviously a lot more sensitive and iso 400 film is more sensitive still.
Is there any chance that long exposures (measured in minutes) could result in light piping through unexposed areas? I doubt this as not all my negatives shot in this way display this issue. But, of my last batch of developed film there was one negative that was more "fogged" than the others and this one happened to be overexposed in camera. Could be a fluke though.
There are two tests that seem obvious to me at this time:
1. Replicate my darkroom conditions for loading film and leave a sheet out for a long time then develop it. Check for any fogging.
2. Use my dark bag to load my film holders. I don't really want to do this because of dust, but I may need to for informational purposes.
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