an easier way of fabricating your own encoder (optical) would be to make a circular pattern with sections that alternate black and white (see attached pic). Then use the optical sensor and interrupts to count every time a white section passes the sensor. In my example, a full rotation of the wheel would need 16 clicks of the optical sensor.
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11) how many "clicks" per revolution would you recommend? This encoder would be used for the drive train most likely, not for the angle of an arm.
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Most arms do not rotate more that 180 degrees, so you may want to look in a potentiometer or gyro for that.