I’m sure you can get well focused results in this way, it it sounds like you are throwing away most of your resolution. Am I missing something? Are you stitching I ages together? If so how are you managing positioning?
If I haven’t missed something: if you compared this to a digital back on a ’blad with otherwise the same image and blew them up I expect the difference would be blindingly obvious.
I would be really interested in hearing more about this (noob in this area). Are you saying the old Nikon / Canon lenses from 90s are a bad choice for modern DSLRs from these companies, or did I completely misunderstand you? If so, why is that?
Using an older lens with a camera sporting a 20+ MP sensor will give you less sharp results than a similar new lens. But the image will be no worse than that old lens shooting film. And the lens will be much cheaper!
If you (or others) like the results, the technical details do not matter.
If a digital SLR and a light table can get you enough resolution for what you want to use the images for though, that's fine. You could use that for most of your images and then get the ones you want to print really large professionally scanned later.
The selling point of bigger sensors now is that they don't need ideal conditions.
A 4x5" negative takes 33 minutes to scan with 2400 dpi. In this time I can make several photos and stitch them together do some spot removal and will get a better quality.
[0] https://www.filmscanner.info/EpsonPerfectionV700Photo.html
One problem with many flatbed scanners (not all of them and not the film scanners) is that they illuminate the film/object from the same side as the sensor, so the light has to travel and bounce more, creating more chances of stray light.
Use a rocket or canned air to keep the dust off, and a sheet of anti-newton glass to keep the film flat and focused while scanning.
Developing B&W at home is economical if you use a shelf-stable developer (I like Kodak HC-110, a half-open bottle keeps for years) and fixer (Ilford Rapid). Per-roll developing cost is between 50¢ and $1.
I shoot a few rolls and throw them in a big Paterson tank. Two rolls of film take 30 min to develop and 15 min to scan. Not much longer than the time to drive round trip to the photo lab.
No darkroom necessary- I load film in a dark bag. Post-process the scans in Lightroom or Darktable. Batch-processing means it's pretty fast. If I want to make prints, either I send out the digital positive to ProDPI or I rent time at the community darkroom.