Gene,
This probably doesn't apply to your situation but when I made the 
encoder wheel for my jet 9x20 lathe (the disc was made from one of 
those non-functional plastic discs they include in a spindle of dvds 
or cds fortunately this one was black)I did the following:

Mount all the interrupters on a piece of pc board which is superglued 
to a little bracket made of aluminum flashing bent till the 
interrupter is straddling the disc and the bracket has a 90 degree 
"foot" which would sit nicely on the cast iron frame of the spindle 
housing if there was some way to attach it.

Take a 3/8 diameter super magnet and put it on the foot.  It will 
hold the aluminum bracket nicely in place for tweeking.

You can now move the spindle and watch the interrupters on the scope 
or with the halscope and tweek them till the duty cycle and 
quadrature is good enough and the index is happpening only once per cycle.

When you are happy apply a drop of super glue between the foot and 
the frame and wait till it sets up.

When it is set then drill and tap the foot for a 6-32 screw and snug it up.

Believe it or not it takes about the same amount of time to do it as 
it takes to describe it.  No math needed. Just put 'em where they 
need to be and nail 'em down.

Cecil


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