It certainly wasn't an exact science back then. I think they just took whatever lots of felt were available at the time (or for the best price), and then went to town. The material was relatively cheap, and likely had some variances from shipment to shipment.
Regarding the size variance, there's a good chance that the image was simply printed a little further down on the pennant, in the case of the second one. That would explain the larger gap between the spine an the graphics. You may say that the first one is still larger... but the second one is clearly altered/trimmed, so we don't really know how big it was in its original state.
Tough to put these shadowy thoughts in writing, but hopefully you get the gist of it. Pennants of this era were not cut with precision, like cards or team-issued photos. Some of these pennants came from street vendors who probably never even got inside the stadium. So there were some definite potential variances. I have lots of unaltered duplicates from the 1940s - 50s that differ in size quite a bit (just like your Giants example).
Eager to hear others' thoughts as well!
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