This time I used proper phototransistors and IR LEDs I scrounged up around the space (thanks, Miria and Raphael!). Because they’re 5mm in diameter (and the spacing between channels is only 2.54mm), I had to come up with a new sensor packing. This one reads bits from four separate columns over a space of five columns, requiring an internal buffer of five columns to reconstruct a single column of data. Even so, the spacing was tight, and I had to sand down the flanges of the phototransistors and LEDs to make everything fit. I milled simple PCBs for both sides to keep things nice and neat, and used a small surface-mount potentiometer to limit the current to the LEDs in case the paper wasn’t thick enough to block enough light. The light mask is made of black acetal this time, and the spacers include runners to help keep the tape straight. There’s still no automatic feed mechanism, but we now have a reader that’s fast and reliable enough to read tapes in earnest.
phooky has a github repository with his design files.