And Camp would have been correct too. I thought I was basically assembling the part upside down... turns out I wasn't but now I need to hybrid the two ideas. The problem with the pulley teeth on the bottom is that the encoder is too high and interferes with the sender/receiver.
Clearly I was on the right track the first time. All I really needed to do was lower the slip ring under the gear (as I did in the first time I heard Camp's voice in my head). The second time I heard "you're doin' it all wrong!" was because I missed the measurement on the optical interrupter cover.
Oh well... As Marvin the Martian says, "well... back to the drawing board." Hey, it's Monday, so my notion that I would be 3D printing today - was not an incorrect assumption!
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