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Does anyone know the size comparison of double sleeved cards compared to single sleeved or no sleeves. I want to know what other options this could hold.
You're in luck. I'm just finishing up sleeving a butt ton of cards so I've recently done some of those measurements.
BCW boxes assume that you get about 56 unsleeved cards per inch (cpi). Using KMC inner sleeves and Ultra Pro Matte outers I have personally seen the following:
Pressed completely flat, no space: 41 cpi
Comfortably snug: 38 cpi
100 card commander deck sitting on a table: 35 cpi.
Your measurements might vary depending on the thickness of the sleeves you use. I' ve noticed the Ultra Pro clear sleeves are thicker than the pro mattes, but haven't sleeved enough clears to measure (I've only done some double sided tokens).
I had trouble finding size ratios when I started all of my sleeving. Everyone talks about how great double sleeving is, but no one talks about how the sizing changes. Mostly (I assume) because a lot of players just sleeve their main decks and a few people sleeve cubes.