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Sure you can. It can be due to the guide bar nose radius or overall bar height, powerhead drive sprocket diameter or number of drives, or a combination of both.
DL frequency is important because of nose sprocket and drive. If you have an 80DL chain then the DLs are gonna be shorter than a chain with 78.
I'm not following you here. Do you mean to say that a chain with 78 drive links is 2 drive links shorter than a chain with 80 drive links? Of course it is. The frequency is important in such that all drive links are spaced evenly to run correctly in your powerhead drive. (Technically, the drive and guide bar sprocket could care less about cutters.)
2nd part. What I'm saying is that a 20" chain with 80DLs has shorter distance between the DLs than a 20" chain with 78DLs IF the actual loops are exactly the same length. This would be directly proportionate to the pitch, of course. Since we have determined that the OP's pitch is the same and the DL count is different, then we can safely say that the old chain and new chain are not of equal length. This is evident, apparently, from eyeballing the bar size differences.
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