A method of selecting inkjet nozzle banks for assembly into an inkjet printhead. The printhead when assembled includes at least two nozzle banks and is operative for printing one particular color ink or other liquid and each nozzle bank includes plural nozzles. The printhead is operational in a printer to print raster rows so that at least one raster row is printed using ink drops deposited at respective different pixel locations on the raster row by respective different nozzles on each of the at least two nozzle banks. The method includes (a) characterizing a drop size parameter for predetermined nozzles of each of the nozzle banks; (b) identifying for each of plural raster rows the respective different nozzles on each of the at least two nozzle banks that would be used to print the respective raster row; (c) identifying a size characteristic associated with each of the plural raster rows using a predetermined computer algorithm without printing the raster rows; and (d) determining in accordance with a criterion and data derived from size characteristic identified in step (c) whether or not the at least two nozzle banks are an acceptable match.