I screwed up when I upgraded from 4.5.1 to 5.1.4, and wound up with thumbnail images only 100px wide. We had been using 480px. I have the settings in 5.1.4 corrected now.
IIRC, when I did the upgrade one of the first steps was to regenerate the thumbnail images? Is it possible to rerun that script with the current settings and generate a larger set of thumbnail images for the old posts?
I did a theme update at the same time, so I may have the two processes confused.
Thanks!