Grizzly H5966 Mandolin Kit Instruction

WARNING

Some dust created by power sanding, sawing, grinding, drilling, and other construction activities contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Some examples of these chemicals are:

• Lead from lead-based paints.
• Crystalline silica from bricks, cement, and other masonry products.
• Arsenic and chromium from chemically treated lumber.

Your risk from these exposures varies, depending on how often you do this type of work. To reduce your exposure to these chemicals: work in a well ventilated area, and work with approved safety equipment, such as those dust masks that are specially designed to filter out microscopic particles.

SECTION 1: SAFETY

WARNING

Always wear safety glasses or goggles when operating equipment. Everyday glasses or reading glasses are not safety glasses. Be certain the safety glasses you wear meet the appropriate standards of the American National Standards Institute (ANSI).

Because there are various ways to cut and join wood, you can make substitutions for the methods stated in this plan. We try to suggest the easiest methods possible. However, only you know your skills with each piece of machinery. Never compromise your safety by using a cutting method with which you are not comfortable. Instead, find an alternative approach that will yield the same result.

WARNING

These instructions assume that you are intimately familiar with the safe operation and use of woodworking machinery and woodworking tools, and understand the techniques used to reproduce this project. If you do not qualify for both of these criteria, STOP building this project for your own safety. Read and understand the owners manual for the machinery you intend to use, take a woodworking class or visit your local library for more information. Woodworking machinery and tools are inherently dangerous because they use sharp edges that can and will cause serious personal injury including amputation and death. Do not underestimate the ability of these tools and machinery to cause injury. Never operate any tool without all guards in place and always wear approved safety glasses. For your own safety, please heed this warning.

SECTION 2: INTRODUCTION

We are proud to offer the Model H5966 Mandolin Kit. This kit is part of a growing Grizzly family of fine woodworking products. When assembled according to the guidelines set forth in this manual, you can expect years of enjoyment from this mandolin.

We are pleased to provide this manual with the Model H5966. It was written to guide you through assembly, review safety considerations, and cover general information. It represents our effort to produce the best documentation possible.

If you have any comments regarding this manual, please write to us at the address below:

Grizzly Industrial, Inc.
C/O Technical Documentation
P.O. Box 2069
Bellingham, WA 98227-2069

Most importantly, we stand behind our products. If you have any questions or parts requests, please call or write us at the location listed below.

Grizzly Industrial, Inc.
1203 Lycoming Mall Circle Muncy, PA 17756
Phone: 570-546-9663
Fax: 800-438-5901
E-mail: techsupport@grizzly.com
Web Site: http://www.grizzly.com

The specifications, drawings, and photographs illustrated in this manual represent the Model H5966 as supplied when the manual was prepared. However, owing to Grizzly’s policy of continuous improvement, changes may be made at any time with no obligation on the part of Grizzly. For your convenience, we always keep current Grizzly manuals available on our website at www.grizzly.com. Any updates to products will be reflected in these manuals as soon as they are complete. Visit our site often to check for the latest updates to this manual!

SECTION 3: PARTS INVENTORY

• Figure 1. Boxed components.
  
  

• Figure 2. Hardware Bags.
  

Supplies/Tools

The majority of the wooden components in this kit are fully machined from the factory and are ready for assembly. A small amount of sanding and finishing will need to be performed to complete the mandolin.

Recommended Tools & Supplies:

• Wood Glue

• 80 to #320 Sanding Paper

• Flexible Sanding Block
• “000” Grade Steel Wool
• Clamps or Rubber Strips (made from cut up inner tubes)
• Drill
• Drill Bits
• Small Brad Nails
• Wire Cutters
• Razor Blade
• Chisel
• Phillips Screwdriver
• Masking Tape
• Razor Saw
• Lightweight Hammer
• Steel Straight Edge
• File Assortment
• Finishing Materials

SECTION 4: SANDING

Body

The mandolin body has been rough sanded at the factory. To get a good finish the body must be  sanded with a series of sandpaper grits.

To sand the mandolin body:

1. Wear an ANSI-approved respirator and safety glasses when sanding wood!

2. Use a sanding block with #150 grit aluminum-oxide sanding paper to sand the mandolin body until there is a consistent scratch pattern on the entire surface. Sand as little as possible in the neck area at this time
   Note— When hand sanding, always sand in the same direction as the wood grain.

3. Resand the entire mandolin body with #220 grit sanding paper and lightly round over the sound hole and edges of the body.

4. Wipe the mandolin body with a damp cloth to “raise” the wood grain, allowing the “raised” grain to be sanded smooth.

5. Wait until the wood is dry and re sand the entire body with #220 grit sandpaper. Dampen again and resand.

6. Fill the wood pores in the back and sides with a paste filler according to the manufacturer’s instructions. DO NOT fill the grain of the spruce soundboard.

7. When the paste filler is dry, use “000” grade steel wool to remove the residue and polish  the wood surface.

Neck

Like the mandolin body, the mandolin neck has been rough sanded at the factory. Personalize the fretboard and neck headstock with additional cutting, inlay, or design work before final sanding. Note—Take your time and consider testing your designs in scrap wood before performing the work on the actual fretboard and headstock.

Wait until the fretboard is installed before sanding the neck.

Fretboard

The fretboard requires no sanding. Note— Sanding the fretboard will affect the playability of the mandolin and could lead to unrepairable damage.

SECTION 5: ASSEMBLY

Neck to the Body

A precise fit is important for the neck-to-body joint. This joint can affect the placement of the strings and bridge, and affect the sound quality of the mandolin. Dry fit and check all the parts before gluing.

To install the neck:

1. Test fit the neck by pushing the dowels into the body of the mandolin and sliding the neck onto the dowels as shown in Figure 3. DO NOT glue the joint at this time.
   Figure 3. Test fitting the neck.
   

2. Check for gaps between the body and the neck.

   • If there are gaps, remove the neck and pegs, hold a piece of sandpaper on the surface of the mandolin body with the grit facing out as shown in Figure 4. Rub the neck up and down on the sandpaper until the neck conforms to the body shape. Be careful to maintain the neck-to-body  angle.
   • If the neck fits tightly, go on to step 3.
     Figure 4. Adjusting the fit of the neck.
     
     

3. Dry fit the neck and place a straightedge along one side. Make a light pencil mark between the F holes as shown in Figure 5. Move the straightedge to the other side of the neck and make another light pencil mark. Note—Make pencil marks that can be sanded off before applying finish.
   Figure 5. Checking neck alignment.
   

4. Measure the widest part of the instrument and lightly mark the center line.

5. Check the neck alignment by measuring from the centerline to both outer marks.

   • If the measurements are equal the neck is perfectly aligned. Move to step 8.
   • If the neck is not aligned move to step 7.

6. Align the neck using the sanding technique described in step 2 and applying extra pressure towards the side of the neck that needs to be shifted. Note—Check the alignment frequently. A little bit of sanding can cause large adjustments.

7. Place the tailpiece on the edge of the soundboard and align it to the center line.

8. Use a screw to mark the centers of the screw holes and then set the tailpiece to the side.
   Note— The tailpiece will not be installed until after the finish is applied to the mandolin, but the alignment of the tailpiece is easier before final sanding.

9. Apply wood glue into the dowel holes in the mandolin body and insert the dowels.

10. Spread a thin layer of wood glue on the heel of the neck, the dowels, and the body where it will connect to the neck.

11. Press the neck firmly onto the dowels

12. Use rubber strips or clamps to hold the neck in place until the glue dries (Figure 6).
    Note— If using clamps, use wooden blocks and pads to protect the instrument.
    Figure 6. Gluing the neck.
    

13. Scrape away the excess glue when it sets up, then allow the glue to dry for 24 hours before the next step

Fretboard Extender

To install the fretboard extender:

1. Press the fretboard extender onto the soundboard and the base of the neck.

2. Check for gaps between the fretboard extender and the body.

   • If there are gaps, place the sandpaper face up on the soundboard. Rub the fretboard extender on the sandpaper until the extender conforms to the body shape as shown in Figure 7. Repeat steps 1–2.
   • If there are no gaps, go on to step 3.
     Figure 7. Fitting the fretboard extender.
     

3. Spread a thin layer of wood glue on the bottom of the fretboard extender and place the extender on the soundboard.

4. Push the fretboard extender against the neck and align them by holding a straightedge on the side of the neck and sliding the fretboard extender against the straightedge.

5. Hold the fretboard extender in place with rubber strips or clamps until the glue dries.
   Note— When using clamps, use wooden blocks and pads to protect the instrument.

6. Scrape away the excess glue when it sets up, then allow the glue to dry for 24 hours.

Fretboard

To attach the fretboard to the neck:

1. Check the neck for flatness by setting the neck on a flat surface, fretboard side down.

   • If there are gaps between the surface and the neck, place sandpaper, grit side up, on the flat surface and rub the neck on the sandpaper as shown in Figure 8 until the neck and fretboard extender are flat.
   • If the neck and fretboard extender are flat, move on to step 2.
     Figure 8. Flattening the neck.
     

2. Align the nut with the angle at the base of the peghead and draw a line along the bottom edge of the nut (Figure 9). Note— It is important to use a very sharp pencil. Try using sandpaper to give the pencil a knife edge.
   Figure 9. Marking the nut position.
   

3. Drill the positioning holes near the ends of the surface of the neck using a drill bit that is slightly smaller than the brad nails used for positioning.
   Figure 10. Alignment pins.
   

4. Nail the brads into the positioning holes and use wire cutters to cut the heads off no more than an 1⁄8″ above the surface of the neck as shown in Figure 10.

5. Center the fretboard on the neck, and align the top with the line drawn in step 2. Note— The neck is wider than the fretboard and will be shaped to match later.

6. Place a wooden block on the fretboard and lightly tap it with a hammer to leave marks in the back of the fretboard.

7. To ensure that you do not drill through the fretboard, use a depth stop or place tape 1⁄8″ from the tip of the drill bit used in step 3. Drill  1⁄8″ deep holes in the marks made in step 6.

8. Spread a light layer of glue on the flat surface of the neck and the back of the fretboard and position the fretboard on the neck using the brad nails as guides.

9. Use rubber strips or clamps to hold the fretboard in place until the glue dries. Note— Use wooden blocks and pads between the  clamps and the neck to protect the instrument.

10. Scrape away the excess glue when it sets up, then allow the glue to dry for 24 hours.

Shaping the Neck

The neck needs to be shaped to match the width of the fretboard and then sanded smooth.

To shape and sand the neck:

1. Put on an ANSI-approved respirator and safety glasses to protect against dust.

2. Use a half round bastard file to shape the neck until it matches the width of the fretboard (Figure 11).
   Figure 11. Shaping the neck.
   
   

3. Use a flexible sanding block with #150 grit aluminum-oxide sanding paper to sand the neck until there is a consistent scratch pattern on the entire surface. Note—When hand sanding, always sand in the same direction as the wood grain.

4. Resand the neck with #220 grit sanding paper.

5. Wipe the neck with a damp cloth to “raise” the wood grain, allowing the “raised” grain to be sanded smooth.

6. Wait until the wood is dry and re sand the neck with #220 grit sandpaper. Dampen again and resand.

7. Fill the wood pores in the neck with a paste filler according to the manufacturer’s instructions.

8. When the paste filler is dry, use “000” grade steel wool to remove the residue and polish the wood surface.

Final Sanding

To prepare the mandolin for finishing:

1. Inspect the entire mandolin under bright lights and take note of any glue residue, dents, scratches, and areas that have not been sanded smooth.

2. Carefully scrape away any glue residue with a sharp chisel held perpendicular to the surface as shown in Figure 12.
   Figure 12. Removing glue residue.
   
   

3. Put on an ANSI-approved respirator and safety glasses for protection against dust.

4. Use #220 grit sandpaper to smooth any flaws found when inspecting the mandolin.

5. Final sand the entire mandolin, except the fretboard, with #320 grit sandpaper. DO NOT sand out the marks for aligning the tailpiece.

Finishing

Finishing supplies are not included with this mandolin kit. Some of the options include stains, lacquers, varnishes and oil finishes. All of these come in spray cans, brush on finishes, or spray finishes. Finish materials and books on finishing instruments can be ordered through Grizzly Industrial or numerous luthier supply catalogs.

To finish the mandolin:

1. Mask off the surface of the fretboard. Carefully press all the masking tape edges securely to the fretboard. The finish coat can seep under these edges, especially near corners, uneven edges, and places where the frets meet the fingerboard.
2. Form a piece of wire into a U shaped hanger with hooks on both ends.
3. Thread the hooks through the upper peg holes and hang the instrument in the finish room.
   Figure 13. Instrument ready to be finished.
   

| WARNING

Wear a NIOSH/OSHA approved respirator with particulate and gas/vapor filters, safety glasses, and rubber gloves, and work in a well ventilated area when using finishing materials!

---|---
4. Apply several thin coats of the finish following the manufacturers instructions. Multiple thin coats usually produce a better quality finish than one heavy coat. 5. Hang the instrument in a dust free room to dry. 6. When finishing is complete, remove the masking tape from the fretboard. 7. Carefully scrape any excess finish off the fretboard with a razor blade as shown in Figure 14.

Painting/Finishing Tips:

Dust particles suspended in the air will settle on wet finishes, causing less than satisfactory results. To avoid this problem:

• Leave the finishing room undisturbed for 24 hours prior to applying the finish.
• Avoid making unnecessary movements upon entering the finish room.
• Apply the finish to the desired mandolin parts and immediately leave the finish room.
• DO NOT return to the room until the specified drying time has elapsed.

Nut

The nut holds the peghead end of the strings the correct distance above the frets. It is not necessary to cut the string notches in the nut that comes with this kit.

To install the nut:

1. Use a chisel to carefully scrape all of the finish out of the nut slot ( Figure 14 ). DO NOT remove any wood from the nut slot.
   Figure 14. Cleaning out the nut slot.
   

2. Spread a thin layer of glue in the nut slot and on the end of the fretboard.

3. Place the nut in the nut slot and hold it in place with rubber strips or clamps until the glue dries. Note— Use wooden blocks and pads between the clamps and the neck to protect the instrument.

4. Wipe away the excess glue before it sets up, then allow the glue to dry for 24 hours.

Tailpiece

The tailpiece holds and separates the ends of the strings. The tailpiece included with this kit is a chrome plated, multi-hook tailpiece with a sliding cover.

To install the tailpiece:

1. Place the tailpiece on the edge of the soundboard and align the screw holes with the marks made earlier.

2. Use three of the small panhead screws to attach the tailpiece. See Figure 15.
   Figure 15. Tailpiece components.
   
   

3. Insert a large countersunk screw through the endpin (strap button).

4. Screw the endpin into the center hole of the tailpiece.

Tuning Machines

To install the tuning machines:

1. Place the eight metal bushings in the pegholes in the front of the headstock as shown in Figure 16
   Figure 16. Peghead bushings.
   
   

2. Place a wooden block on the bushing and hammer the block until the bushing flange is flush with the peghead surface.

3. Turn the mandolin over and insert the tuning machines into the back of the pegholes.

4. Attach both tuning machines to the peghead with ten of the small screws.
   Figure 17. Tuning machines installed in the peghead.
   

Bridge

This mandolin has a scale of 350 mm, which means that the bridge will be placed 350 mm from the nut. This will be approximately between the points of the sound holes. Mandolin bridges are not glued into place, but are held in place with the string pressure, so final placement of the bridge occurs when the strings are tuned.

To fit the bridge to the soundboard:

1. Place a piece of sandpaper, grit side up, between the points of the F holes.

2. Remove the bridge top.

3. Hold the sandpaper firmly (so that you will not mar the finish) and move the bridge back and forth, perpendicular to the string direction as shown in Figure 18.
   Figure 18. Fitting the bridge to the soundboard.
   
   

4. When the ebony dust streaks on the sandpaper are the same width as the soundboard, take shorter sanding strokes.

5. Remove the sandpaper and place the bridge on the soundboard. Look for gaps between the bridge and the soundboard. Repeat steps 3-5 until there are no gaps.

Winding Strings

Install the mandolin strings loosely. The bridge must be installed and adjusted before the strings can be tightened and tuned.

To install the mandolin strings:

1. Place the end of the string with the loop over the hooks on the tailpiece as shown in Figure 19. Work from the thinnest string (E string-treble) to the thickest (G string-bass).
   Figure 19. String placement.
   

2. Route the strings over the bridge and to the inside of the tuning posts. Note— Allow enough string slack to allow 2-3 complete winds around the tuning peg.

3. Insert the end of the string into the tuning post and turn the knob to tighten the strings. Note—DO NOT completely tighten the strings at this time.

Bridge Placement

To place the bridge:

1. Lay the bridge flat on the mandolin head and slide it under the strings.

2. Slowly tilt the bridge up under the strings.
   Note— Loosen the strings if it is difficult to raise the bridge.

3. Slide the strings into their slots and tune.

4. The bridge is located 350 mm (13.8″) from the nut and 175 mm (6.89″) if measured from the 12th fret. See Figure 20.
   Figure 20. Bridge placement.
   

5. Finalize the position of the bridge by lightly touching the 1st string directly above the  twelfth fret and plucking the string to play a harmonic note.

6. Now pluck the string while holding it against the twelfth fret. If this note is sharper than the note played in step 5, move the bridge toward the tailpiece. If this note is flat in comparison, move the bridge toward the neck.
   Note— The bridge may need to be slightly angled for the best sound.
   Note— This can also be done with an electronic tuner by tuning the harmonic note to be exactly in tune and then adjusting the bridge until the note played in step 6 is also in tune.

String Height

Correct string height is crucial to prevent fret buzz and maximize playability. The string height is measured from the top face of the fret and the bottom of the string. The string height at the 12th fret from the peghead should be 5⁄64″ (2 mm) to 7⁄64 ” (3 mm) above the fret.

• Figure 21. String height measurement.
  

To check the string height:

1. Measure by placing a nickel (approximate thickness of a nickel is 5⁄64″) between the fret and the string.
   Figure 22. Correct 12th fret string heights.
   

2. Adjust the barrel nuts on the bridge until the string height is correct. Note— You may need to loosen the strings to adjust the bridge.

Tuning

Tuning is the most important aspect of performance for a mandolin. If the mandolin is not in tune with itself, or the other instruments in an ensemble, the resulting music will not sound pleasing to the ear. The standard mandolin tuning notes are shown in Figure 23.

• Figure 23. Standard tuning notes.
  

Important issues to consider when tuning a mandolin:

• Get into the habit of tuning the mandolin every time it is picked up to be played.
• Always tune the strings “up.” The final tuned tension of each string should be reached while tightening the string, not loosening it. If the string is tensioned too far, loosen the tension and tune ”up” again.
• The easiest way to tune a mandolin is using an electronic tuner such as the Grizzly H3097 Chromatic Tuner shown.

Pickguard

To install the pickguard:

1. Attach the metal bracket to the pickguard with the machine screw as shown in Figure 24.
   Figure 24. Attaching the metal bracket.
   

2. Place the pickguard against the neck extension so the tip of the pickguard lines up with the inside edge of the binding (Figure 25).
   Figure 25. Pickguard placement.
   

3. Screw the short countersunk Phillips head screw into the hole at the head of the pickguard.

4. Adjust the metal bracket so the pickguard is parallel with the neck, and the bracket is tight against the side of the mandolin body.

5. Attach the metal bracket to the body with a long countersunk Phillips head screw.

6. Slide the felt button between the pickguard and the soundboard until it is tightly wedged.

SECTION 6: REFERENCE INFO

General

If you need parts or help in assembling your mandolin, or if you need operational information, call our service department at 570-546-9663. Trained service technicians will be glad to help you.

If you have any comments regarding this manual, please write to Grizzly at the address below:
Grizzly Industrial, Inc.
C/O Technical Documentation
P.O. Box 2069
Bellingham, WA 98227-2069

We recommend you keep a copy of our current catalog for complete information regarding Grizzly’s warranty and return policy. If you need additional technical information relating to this mandolin, or if you need general assistance or replacement parts, please contact the Service Department at the location listed below.

Grizzly Industrial, Inc.
1203 Lycoming Mall Circle
Muncy, PA 17756
Phone: 570-546-9663
Fax: 800-438-5901
E-mail: techsupport@grizzly.com
Web Site: http://www.grizzly.com

Supplies and Accessories

• Figure 26. Model H3097 Chromatic Tuner.
  

• Figure 27. Model H5750-59 McFadden’s Lacquers and Fillers.
  

• Figure 28. Assorted sandpaper is available in the Grizzly catalog.
  

Warranty & Returns

Grizzly Industrial, Inc. warrants every product it sells for a period of 1 year to the original purchaser from the date of purchase. This warranty does not apply to defects due directly or indirectly to misuse; abuse; negligence; accidents; repairs or alterations; assembly, finishing or modification of kits; or lack of maintenance. This is Grizzly’s sole written warranty and any and all warranties that may be implied by law, including any merchantability or fitness, for any particular purpose, are hereby limited to the duration of this written warranty. We do not warrant or represent that the merchandise complies with the provisions of any law or acts unless the manufacturer so warrants. In no event shall Grizzly’s liability under this warranty exceed the purchase price paid for the product and any legal actions brought against Grizzly shall be tried in the State of Washington, County of Whatcom.

We shall in no event be liable for death, injuries to persons or property or for incidental, contingent, special, or consequential damages arising from the use of our products.

To take advantage of this warranty, contact us by mail or phone and give us all the details. We will then issue you a “Return Number,’’ which must be clearly posted on the outside as well as the inside of the carton. We will not accept any item back without this number. Proof of purchase must accompany the merchandise.

The manufacturers reserve the right to change specifications at any time because they constantly strive to achieve better quality equipment. We make every effort to ensure that our products meet high quality and durability standards and we  hope you never need to use this warranty.

Please feel free to write or call us if you have any questions about the machine or the manual.

Thank you again for your business and continued support. We hope to serve you again soon.

Customer Support

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GRIZZLY INDUSTRIAL, INC.
P.O. BOX 2069
BELLINGHAM, WA 98227-2069

COPYRIGHT © MARCH, 2004 BY GRIZZLY INDUSTRIAL, INC.
WARNING: NO PORTION OF THIS MANUAL MAY BE REPRODUCED IN ANY SHAPE OR FORM WITHOUT THE WRITTEN APPROVAL OF GRIZZLY INDUSTRIAL, INC.
JOB #6099 PRINTED IN JAPAN

References

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