I used the black "dummy" CD or DVD (cant remember which) that comes 
in a new stack of disks to make my encoder disk.
I cut 20 equally spaced notches about .15 inch deep and made one of 
them about .45 deep for the index.  I used TTL output optical 
interrupters to read the disk with 2 for quadrature and one for 
index.  The disk is very easy to cut and it runs true without 
worrying about it wobbling.  I cut mine on my cnc'd Millrite with a 
cnc rotary table but you could easily lay out and file the notches in 
less time than it took me to write the code and set up the table on the mill.
I mounted the interrupters on very thin little aluminum plates and 
held them onto the machine with supermagnets. When I had confirmed 
the timing of A and B for quadrature and made sure the index wasn't 
picking up the shallow notches I put a couple of drops of superglue 
on the edge of the aluminum plate.  When it had set I removed the 
magnets and drilled the plates for mounting screws with complete 
assurance that they would be rigidly mounted in the right place.

I used this technique on the spindle of a Jet 9 x 20 and also on my 
Monarch 10EE.  They are both very happy.

Cecil

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