Grizzly H5966 User Manual
MANDOLIN KIT
MODEL H5966
INSTRUCTION MANUAL
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
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 fil
ter out microscopic particles.
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Table of Contents
SECTION 1: SAFETY ....................................................................................................................... 2
SECTION 2: INTRODUCTION .........................................................................................................
SECTION 3: PARTS INVENTORY ...................................................................................................
Supplies/Tools ............................................................................................................................ 4
SECTION 4: SANDING ....................................................................................................................
Body ........................................................................................................................................... 5
Neck ........................................................................................................................................... 5
Fretboard .................................................................................................................................... 5
SECTION 5: ASSEMBLY .................................................................................................................
Neck to the Body ........................................................................................................................
Fretboard Extender ....................................................................................................................
Fretboard .................................................................................................................................... 8
Shaping the Neck .......................................................................................................................
Final Sanding .............................................................................................................................
Finishing ................................................................................................................................... 10
Nut ............................................................................................................................................ 11
Tailpiece ................................................................................................................................... 11
Tuning Machines ......................................................................................................................
Bridge ....................................................................................................................................... 12
Winding Strings ........................................................................................................................
Bridge Placement .....................................................................................................................
String Height ............................................................................................................................
Tuning ...................................................................................................................................... 14
Pickguard ................................................................................................................................. 15
SECTION 6: REFERENCE INFO ...................................................................................................
General ..................................................................................................................................... 16
Supplies and Accessories ........................................................................................................
Notes ........................................................................................................................................ 17
Warranty & Returns ..................................................................................................................
Warranty Card ...........................................................................................................................19
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SECTION 1: SAFETY
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 appropri
ate 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.
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 wood
working 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 machin
ery 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.
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H5966 Mandolin Kit
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 pre
pared. 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!
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H5966 Mandolin Kit -3-
SECTION 3: PARTS INVENTORY
REF PART # DESCRIPTION
1 PH5966001 Mandolin Body
2 PH5966002 Neck
3 PH5966003 Fretboard
4 PH5966004 Bridge
5 PH5966005
6 PH5966006 Pickguard Assembly
7 PH5966007 Nut
8 PH5966008 Endpin with Screw
9 PH5966009 Dowels
10 PH5966010 Strings
11 PH5966011 Tailpiece with Screws
12 PH5966012 Fretboard Extender
13 PH5966013 Tuning Machine Bushings
Tuning Machines with Screws
Supplies/Tools
1
2
3
10
Figure 1. Boxed components.
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5
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4
11
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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 fin
ishing 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
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Figure 2. Hardware Bags.
H5966 Mandolin Kit
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 alumi
num-oxide sanding paper to sand the man
dolin 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.
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
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sanding the neck
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Fretboard
The fretboard requires no sanding. Note—
Sanding the fretboard will affect the playability
of the mandolin and could lead to unrepairable
damage.
5. Wait until the wood is dry and resand 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.
H5966 Mandolin Kit -5-
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 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
5. Move the straightedge to the other side
of the neck and make another light pencil
mark.
sanded off before applying finish.
Note—Make pencil marks that can be
Figure
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
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Figure 5. Checking neck alignment.
5. Measure the widest part of the instrument
and lightly mark the center line.
6. 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
– If the neck is not aligned move to step
H5966 Mandolin Kit
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8.
7.
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