On Fri, 4 Jul 2014 19:45:31 -0500, you wrote:

>That would be large enough to have some physical instability at high speed.
>You could also have room to put a number of pickups around it and gain
>resolution by reading them sequentially.

I have an encoder disk made of tufnel on my lathe - it's around 7"
diameter 4mm thick. No problems at 4000 rpm.

I only made it as I couldn't get hold of a low count encoder at a
reasonable price and I had some lying around along with dozens of
slotted opto switches. 

Nice thing is it's easy to machine, did the 120 encoder slots with a new
disposable 3mm HSS 2 flute endmill in one pass, then the center and
mounting holes and finally cut it out all with the same tool. The index
slot is twice the length of the others and that opto is mounted further
in than the A & B ones.
 

Steve Blackmore
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