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You might try gearing the pot to the device you are trying to measure.
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Yeah, I think that is what will have to be done. Right now the team is in a mindset where the control of mechanical parts are not part of their design. So the software guys are supposed to take the mechanicals final product and figure out ways to add sensors. Some devices are even given to us saying, "this can not run against the mechanical stop," without thought of where they could put a sensor. I'm sure all this is pretty typical.
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Can you just look at the most significant bits and get a good reading.
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We could, if we could even pick up the MSB ;o)