A narrow track width read sensor having a high magnetoresistive
sensitivity is made using a self-aligned process which requires the use
of only a single resist mask. A plurality of sensor layers which includes
a top layer of noble metal is deposited over a substrate. Optionally, a
central protective barrier which is conductive or reactive-ion-etchable
is formed over these sensor layers. After forming a resist mask in the
central region, first lead layers are deposited in the end regions and
over the resist mask. Using the resist mask, ion milling is performed
such that the first lead layers and sensor layers in the end regions are
substantially removed but sensor layers in the central region remain, to
thereby form a read sensor having lead overlays on the edges thereof.
Hard bias and second lead layers are then deposited in the end regions
and over the resist mask. After the resist mask is removed, the top of
the read sensor may be oxidized through an exposure to oxygen plasma such
that the magnetoresistive sensitivity of the read sensor is increased.
Alternatively, the top layers of the read sensor may be removed or
transformed by reactive ion etching (RIE).