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
Page 2
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.
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
Page 5
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!
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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9
7
Figure 2. Hardware Bags.
H5966 Mandolin Kit
Page 7
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
-
-
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.
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-
Page 8
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
-6-
.
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
.
8.
7.
Page 9
7. Align the neck using the sanding technique
described in step 2 and applying extra pres
sure 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.
8. Place the tailpiece on the edge of the
soundboard and align it to the center line.
9. 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.
8. Apply wood glue into the dowel holes in the
mandolin body and insert the dowels.
9. 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.
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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 extend
er 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
.
-
.
10. Press the neck firmly onto the dowels.
11. 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.
12. Scrape away the excess glue when it sets
up, then allow the glue to dry for 24 hours
before the next step.
.
Figure 7. Fitting the fretboard extender.
3. Spread a thin layer of wood glue on the bot-
tom of the fretboard extender and place the
extender on the soundboard.
4.
Push the fretboard extender against the neck
and align them by
the side of the neck and sliding the fretboard
extender against the straightedge
Hold the fretboard extender in place with
5.
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.
holding a straightedge on
.
.
H5966 Mandolin Kit-7-
Page 10
Fretboard
To attach the fretboard to the neck:
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.
1. Check the neck for flat
ness 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 10. Alignment pins.
4. Nail the brads into the positioning holes and
use wire cutters to cut the heads off no more
1
than an
shown in Figure 10
⁄8" above the surface of the neck as
.
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.
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 impor
tant to use a very sharp pencil. Try using
sandpaper to give the pencil a knife edge.
Peghead
Angle
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
1
-
from the tip of the drill bit used in step 3. Drill
1
⁄8" deep holes in the marks made in step 6.
fretboard, use a depth stop or place tape
⁄8"
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 instru
-
ment.
6. Scrape away the excess glue when it sets
up, then allow the glue to dry for 24 hours.
-8-
Figure 9. Marking the nut position.
H5966 Mandolin Kit
Page 11
Shaping the Neck
7. Fill the wood pores in the neck with a paste
filler according to the manufacturer's instruc
.
tions
-
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.
Use a half round bastard file to shape
2.
the neck until it matches the width of the
fretboard (Figure 11).
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 sur
as shown in Figure 12.
face
-
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 pat
tern 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 resand the
neck with #220 grit sandpaper. Dampen
again and resand.
-
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.
H5966 Mandolin Kit-9-
Page 12
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 finish
ing 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 pegholes and hang the instrument in the finish
room.
Wear a NIOSH/OSHA
approved respirator with
particulate and gas/vapor
filters, safety glasses,
and rubber gloves, and
work in a well ventilated
-
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:
.
area when using finish-
ing materials!
Figure 13. Instrument ready to be finished.
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.
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H5966 Mandolin Kit
Page 13
Nut
Tailpiece
The nut holds the peghead end of the strings the
correct distance above the frets. It is not nec
essary 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 fin
ish out of the nut slot (Figure 14). DO NOT
remove any wood from the nut slot.
The tailpiece holds and separates the ends of
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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 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.
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.
H5966 Mandolin Kit-11-
Page 14
Tuning Machines
Bridge
To install the tuning machines:
1. Place the eight metal bushings in the peg
holes 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.
.
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 direc
tion as shown in Figure 18
.
-
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.
Figure 18. Fitting the bridge to the soundboard.
4. When the ebony dust streaks on the sandpa
per 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.
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-12-
H5966 Mandolin Kit
Page 15
G
D
A
E
Winding Strings
Bridge Placement
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
string-treble) to the thickest (G string-bass).
the thinnest string (E
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 19. String placement.
3. 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.
4. Insert the end of the string into the tun
ing post and turn the knob to tighten the
strings. Note—DO NOT completely tighten
the strings at this time.
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 com
parison, move the bridge toward the neck.
Note—The bridge may need to be slightly
angled for the best sound.
—This can also be done with an electronic
Note
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.
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H5966 Mandolin Kit-13-
Page 16
G
D
A
E
4
3
2
1
String Height
Tuning
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
7
⁄64" (3 mm) above the fret.
String Height
Fretboard
Figure 21. String height measurement.
To check the string height:
Measure by placing a nickel (approximate
1.
thickness of a nickel is
and the string.
5
5
⁄64"
5
⁄64" (2 mm) to
String
Fret
⁄64") between the fret
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.
Mandolin Body
7
5
⁄64"
12th Fret
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.
-14-
String Heights:
⁄64"–
• 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 on page 16
H5966 Mandolin Kit
.
Page 17
Pickguard
To install the pickguard:
1.
Attach the metal bracket to the pickguard with
the machine screw as shown in Figure 24
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
.
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.
side of the mandolin body.
Figure 24. Attaching the metal bracket.
2. Place the pickguard against the neck exten-
sion so the tip of the pickguard lines up with
the inside edge of the binding (Figure 25).
Figure 25. Pickguard placement.
H5966 Mandolin Kit-15-
Page 18
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 cur
rent 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.
Supplies and
Accessories
Figure 26. Model H3097 Chromatic Tuner.
-
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
.
Figure 27. Model H5750-59 McFadden's
Lacquers and Fillers.
Figure 28. Assorted sandpaper is available in
the Grizzly catalog.
-16-
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H5966 Mandolin Kit
H5966 Mandolin Kit
Page 19
Notes
H5966 Mandolin Kit-17-
Page 20
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; negli
gence; 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 war
ranty. 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.
-18-
H5966 Mandolin Kit
Page 21
Warranty Card
Name _____________________________________________________________________________________
Street _____________________________________________________________________________________
City _____________________________________________________________ State________Zip_________
Phone Number_______________________E-Mail_______________________FAX__________________
MODEL #______ _________ _________ _________ _________ _____ Order #______________________
The following information is given on a voluntar y basis. It will be used for marketing purposes to help us develop better products and services. Of