Grizzly H8066 User manual

MODEL H8066
MANDOLIN KIT
WITHOUT HOLES
OWNER'S MANUAL
COPYRIGHT © NOVEMBER, 2006 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.
#BL8553 PRINTED IN JAPAN

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SECTION 1: SAFETY ....................................................................................................................... 2
SECTION 2: INTRODUCTION ......................................................................................................... 3
Foreword .................................................................................................................................... 3
Contact Info ................................................................................................................................ 3
SECTION 3: PARTS INVENTORY ................................................................................................... 4
Inventory ..................................................................................................................................... 4
Supplies/Tools ............................................................................................................................ 4
Identification ............................................................................................................................... 5
SECTION 4: ASSEMBLY ................................................................................................................. 6
Shaping Body ............................................................................................................................. 6
Assembling Body ....................................................................................................................... 7
Attaching Binding ....................................................................................................................... 9
Sanding Body ........................................................................................................................... 10
Sanding Neck ........................................................................................................................... 10
Fretboard .................................................................................................................................. 10
Neck to Body ............................................................................................................................ 11
Fretboard .................................................................................................................................. 14
Shaping Neck ........................................................................................................................... 15
Shaping Fretboard ................................................................................................................... 16
Final Sanding ........................................................................................................................... 17
Finishing ................................................................................................................................... 17
Nut ............................................................................................................................................ 18
Tailpiece ................................................................................................................................... 19
Tuning Machines ...................................................................................................................... 19
Fitting Bridge ............................................................................................................................ 20
Installing Strings ....................................................................................................................... 20
String Height ............................................................................................................................ 22
Tuning ...................................................................................................................................... 23
Adjusting F-Holes ..................................................................................................................... 23
SECTION 5: REFERENCE INFO ................................................................................................... 26
Accessories .............................................................................................................................. 26
WARRANTY AND RETURNS ........................................................................................................ 29
Table of Contents

-2- H8066 Mandolin Kit Without Holes
SECTION 1: SAFETY
These instructions assume that you are intimately familiar with the safe operation and use of wood-
working 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.
Always wear safety glasses or goggles when operating equipment. Everyday glasses or read-
ing 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.

H8066 Mandolin Kit Without Holes -3-
SECTION 2: INTRODUCTION
If you have any comments regarding this manual,
please write to us at the address below:
Grizzly Industrial, Inc.
C/O Technical Documentation Manager
P.O. Box 2069
Bellingham, WA 98227-2069
Email: [email protected]
We stand behind our products. If you have any
service 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: [phone]
Fax: [phone]
E-Mail: [email protected]
Web Site: http://www.grizzly.com
Contact Info
Foreword
We are proud to offer the Model H8066 Mandolin
Kit Without Holes. This kit is a part of a growing
Grizzly family of fine woodworking projects. When
assembled according to the guidelines set forth in
this manual, you can expect years of enjoyment
from your mandolin.
We are pleased to provide this manual for the
Model H8066. It was written to guide you through
assembly, review safety considerations, and cover
general information. It represents our effort to pro-
duce the best documentation possible.

-4- H8066 Mandolin Kit Without Holes
The majority of the wood components in this kit
come fully machined and ready for assembly. A
small amount of sanding and finish work is need-
ed to complete the mandolin.
Recommended Tools & Supplies:
• Wood Glue—Titebond Original Wood Glue
• #80 to #320 Sanding Paper
• Flexible Sanding Block
• “000” Grade Steel Wool
• Clamps (carriage bolts, wing nuts, flat wash-
ers, wood blocks)
• Rubber Strips (cut up inner tubes)
• Electric/Cordless Drill
• Drill Bit (1/16")
• Small Brad Nails
• Wire Cutters
• Razor Blade
• Chisel
• Phillips Screwdriver
• Masking Tape
• Lightweight Hammer
• Rubber Dead Blow Hammer
• Steel Straight Edge
• Sharp Pencil
• File Assortment
• Finishing Materials
• Electronic Tuner
• Coat Hanger
• NIOSH Approved Respirator
• ANSI-Approved Safety Glasses
SECTION 3: PARTS INVENTORY
Figure 1. Boxed components.
Figure 2. Additional components.
Supplies/Tools
REF PART # DESCRIPTION QTY
1 PH8066001 Neck 1
2 PH8066002 Fretboard 1
3 PH8066003 Fretboard Extender 1
4 PH8066004 Tuning Machine 2
5 PH8066005 Top 1
6 PH8066006 Rim 1
7 PH8066007 Backboard 1
8 PH8066008 Bridge Assembly 1
9 PH8066009 Pickguard 2
10 PH8066010 Pickguard Bracket 1
11 PH8066011 Wood Block 1
12 PH8066012 Binding 2
13 PH8066013 Dowel 3
14 PH8066014 Nut 1
15 PH8066015 String 8
16 PH8066016 Tailpiece 1
17 PH8066017 Tailpiece Cover 1
18 PH8066018 Endpin 1
19 PH8066019 Bushing 8
20 PH8066020 Chrome Screw #3 x 3/4" 2
21 PH8066021 Black Screw #3 x 3/4" 1
22 PH8066022 Chrome Screw #1 x 3/8" 14
23 PH8066023 Phlp. Hd. Scr M3-.5 x 4 1
1
23
4
5
6
7
11
12
18
Inventory
14
15
16
17
19
20
23 10
22
13
21
9
8

H8066 Mandolin Kit Without Holes -5-
Identification
Tuner or Tuning
Machine
Headstock
or Peghead
Neck
Tailpiece
Fret
Tuning Peg
Figure 3. Model H8066 main features.
Figure 4. Model H8066 headstock features.
Endpin
Barrel Nut
Bridge

-6- H8066 Mandolin Kit Without Holes
SECTION 4: ASSEMBLY
Shaping Body
The f-holes are cut into the top to aid air flow
through the mandolin.
Components and Hardware Needed: Qty
Top ................................................................... 1
Backboard ......................................................... 1
Rim ................................................................... 1
To make the f-holes:
1. Place the top face down, then place the rim
onto the top so the notches in the rim fit over
the tone bars.
Note: The ends of the tone bars will stick
out. The head block should be about 1⁄8" back
from the edge of the top.
2. Using a pencil, mark the outside edge of the
rim onto the top. This line will identify where
the two pieces meet as shown in Figure 5.
Figure 5. Marking outline of rim onto top.
4. Use a bandsaw or jig saw to cut the top to
a rough shape. Be careful to cut only to the
edge of your pencil mark.
5. Choose an f-hole pattern. Refer to Page 25
for sample f-hole shapes.
6. Draw two f-holes onto the inside of the top as
shown in Figure 6.
Typically the bass f-hole is closer to the tone
bar than the treble f-hole is to the treble tone
bar. Make sure the f-holes do not extend into
the tone bars or past the top edge (drawn in
Step 1).
Tip: Use carbon paper to transfer the f-hole
outline onto the top. Place low adhesion
painting tape over the inside of the top to
reduce tear out when you cut the holes.
Figure 6. Using carbon paper to trace f-holes
onto inside of top.
3. Remove the rim.
Tone
Bars
Headblock
Bass Tone
Bar
Treble Tone
Bar
Rim
Top
F-hole
patterns

H8066 Mandolin Kit Without Holes -7-
Figure 7. Cutting the f-holes.
7. Drill a hole into the f-hole ends, then cut them
out carefully with a scroll saw or jig saw, mak-
ing sure you stay inside the lines, as shown in
Figure 7.
Tip: Drilling additional holes near the tight
corners of the f-holes can help you cut them
out more easily.
Components and Hardware Needed: Qty
Top ................................................................... 1
Backboard ......................................................... 1
Rim ................................................................... 1
To assemble the top, rim, and backboard:
1. Place the backboard face down, then place
the rim over the backboard so the notches in
the rim fit over the ends of the tone bar.
2. Mark the outside edge of the rim onto the
backboard. Make sure the waste cut area is
even around the edge of the backboard.
3. Remove the rim.
Assembling Body
Figure 8. Cutting backboard to rim outline.
4. Use a bandsaw or jig saw to cut the edge
of the backboard close to the rim outline as
shown in Figure 8.
Note: Be careful to cut up to but not past the
outline.
Figure 9. Drilling positioning holes.
5. Drill positioning holes 1/2" deep into the center
of the headblock and tailblock on both sides
for positioning brad nails (Figure 9).
Note: The brads will help keep the top and
backboard from moving after they are glued.
Make the hole diameters slightly smaller than
the brads.
Tailblock
8. Use a fine metal file or rolled up piece of fine
grit sandpaper to smooth the inside edge of
the f-holes. Do not remove too much mate-
rial, because you will smooth the f-hole aper-
tures after the body is assembled. (See Page
23 for f-hole adjustments.)
Outline
Headblock

-8- H8066 Mandolin Kit Without Holes
6. Nail the brads into the positioning holes and
use wire cutters to cut the heads off no more
than 1⁄16" above the surface of the neck as
shown in Figure 10.
Figure 10. Brads nailed into the headblock and
tailblock.
7. Place the rim over the top, making sure the
rim does not protrude beyond the top edge.
8. Lightly tap the rim with a rubber dead blow
hammer to leave brad marks on the inside of
the top.
9. Repeat Steps 6–8 with the backboard.
10. Spread a thick layer of wood glue such as
Model H5332 on the top and bottom of the
rim, and the outside edges of the top and
backboard.
11. Position the top and backboard onto the rim
using the brad nails as guides.
Figure 11. Top, rim, and backboard clamped
together.
12. Place screw clamps around the rim and a C-
clamp over the headblock, then tighten them
to hold the top and backboard in place until
the glue dries, as shown in Figure 11.
Fit as many screw clamps onto the mando-
lin body as possible to ensure even contact
between the wood surfaces.
Note: You can make screw clamps from car-
riage bolts, wing nuts, flat washers, and wood
blocks or discs. Keep the blocks away from
the fragile edges of the f-holes so you don't
break or crack them.
13. Scrape away excess glue, then allow the glue
to dry according to the glue manufacturer's
curing instructions.
14. Remove the clamps and fill in any gaps in the
glue seam with a paste filler, then sand down
when dry.
Brads
Screw
Clamp