I forgot to post an update to this story. The hex-bore versa encoders worked perfectly all the way through champs. They allowed us to implement our low-goal auto (
https://www.youtube.com/watch?v=muoSbQza0zQ) which was key to our excellent performance in Carson. There are a couple of caveats though:
- The versa planetary encoder housing is pretty flexible. It was a bit too easy to clamp it down in a way that pushed the internal magnet out of alignment. (Having a coloured light indicator for alignment was a big help though). Next year we might design and print a new housing, as well as the hex bore gear
- The 6" ribbon cable limit really sucks. We built extension cables using breakout boards and pwm cables, but that makes for an expensive and time-consuming cable!
Otherwise I was pretty happy with these hacked encoders. They will be especially useful if we switch to a cantilevered live axle (west-coast drive) next year.