K-
a good thing to keep in mind is that perfecting a screen, or better yet a screened print, is all about paying attention to the variables. only change one at a time, and keep records of the changes. just like the scientists do it.
for the larger screen, move the light source away from the screen so that it still bathes the entire thing in light, and guess your new exposure time. use the results for the next guess, till you get it right.
or search the forums for
exposure test.
when you switch emulsions, you will have to perform the tests all over again. but you will most likely find there is a better emulsion for you out there, based on your setup. i'd reccomend calling Ulano for any emulsion questions. they haven't steered me wrong yet.
once you have understood all the variables, you will continue to get consistent results. and it will be easier to pinpoint a problem when one comes up.
hope this helps.