The mounted pulley is flush just like the CAD. However, I found an issue with the support material because my second pass on the design just wasn't good enough for manufacturability. I need really flat surfaces from the raft on the encoder to improve the overall print quality.
I have separated the pulley pins into threaded rods, and I am using them to the mount the lidar on top of the pulley as well.
The isolation ring on the bottom has become it's own slip in part. I will likely have to epoxy it into the channel for now. This will provide prints with zero support material for the encoder wheel - and this should reduce the noise on the sensor by quite a lot. I may add snap tabs (like I already did for the lidar mount).
The top of the pulley also has the three snap tabs. I am quite please with how these turned out. They snap right into to the lidar mount and the fit is pretty snug. I seem to have sized it very closely.
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