How do you make your best board better, order a custom version!

2013 Tabou 240 X 59 88ltr

What do you do when you favorite board is just a bit too thick, or thin for your body weight?

This is a common problem that small, and large men, and and most women have.

I get this all the time, “can you make me a board just like this, but make it a bit smaller, larger, faster, more maneuverable etc, etc.

This is an example of how we work with our customers, to help them have the most fun on the water.

It started with a conversation about my customers 2013 88 ltr Tabou Manta Slalom board, he loved the way it sailed, but it was 10 mm thicker than the previous version, and that was just too thick for his body weight.

So he asked if I could make a scaled version, and this is how I went about it.

First, I measured his board, this meant the rocker, thickness flow, outline, bottom shape, rail shape, insert locations, and finally the deck concave.

2013 Tabou 240 X 59 88ltr


Next was to create a digital version oh his production board.  It turned out to be 88.7  ltrs.


Tabou Production 88ltr SL plan shape info


Then I created a new sub-file for my customer, thinned it out, but we did not want the  mid to nose to be too thin, so I reduce the depth of the deck concave to make sure we did not loose too much volume.  Note, the outline, rocker, bottom shape, and rail shape from the apex of the down remained the same.  Below is a screen shot of the mid slice showing how the deck was thinned out.

mid slice comparison


And here is the profile, showing how we eliminated the extra volume, yet still kept the rest of the board the same.

scaled down profile


And finely, here is a shot of the deck concave, as a result, the depth of the deck concave has been reduced by close to 50 percent.

deck concave compromise


The end result is that the board has reduced in volume from 88.7 ltrs, down to 83.4 ltrs.

scaled down plan shape 83.4 ltr

3D view


If you are like my customers, and would like something custom tailored specially to you, give us a call, if you can dream it up, we can build it!

We just milled our 4,000th board!!!!

We just hit 4,000 !!!!!

We just hit 4,000 !!!!!




Full ShopShop full of blanks.

Nelson Factory Customer pays tribute to his niece

Ed at the beach

One of our best customers from Chicago recently had his niece pass, and wanted to do a tribute to her to keep her spirit with him as he is sailing.

We were already in the process of making him a new 116 liter board for sailing in the demanding conditions in Chicago, so we were happy to help.

Ed at the beach

Ed also was able to write on the tail of the board prior to completion.


This was the artwork he submitted for the deck of his board.  Fernando Messera is the artist that help us.


This the the master plan shape for his new board, his local sailing spot is very demanding, and requires drifting out to the wind line, then deal with extremely copy conditions, lots of wind shifts, and then drift home, not to mention the cold water.  No wonder he comes to Maui two to three times a year!

Ed's Blaster Ride

And here are some words from ED:

The design of the board is a tribute in memory of my niece Delaney who died
this past July suddenly and accidentally.

I think that having a Nelson Custom made not only fulfilled my personal need
to match the style and conditions in which I will use the board, it also
gave me an opportunity to make a statement with the graphics.

 I have been able to add a graphic design element to my 4 Nelson Customs to
make them truly unique and personal. Add that to the quality of the board
and the excellent design and I have a quiver of winners.

Thanks Mark for making this possible.

Ed Coyne


2014 Nelson Factory Sail Sticker Kit

2014 sail sticker kit

2014 sail sticker kitCheck out the new Nelson Factory Sail Sticker Kit.

Sail Kits are $25.00 plus shipping.

The main banner is 20.5″ X 4.5″

The big logo is 18.5″ wide X 16.75″ tall

Kits come with application paper already applied.

Final sail logo

And here are the colors you can choose from, we also have Chrome, and Red Chrome for an extra $10.00 per set.

Vinyl colors

2014 Speed Board


Check out our new open ocean speed board!

If you want to break 36 knot’s and get into the 40’s, then drop us a line.

Here is the profile and outline.





 We re-mill the bottom once the deck sandwich is on, to ensure the most accurate bottom shapes available.







Bill Foote’s custom Maliko 14

3.5 Bottom Lam

Bill Foote is a leader in downwind SUP designs, and we are stoked to work with him over the years to help him and his customers get of some of the best boards in the world!

If you would like more information about a custom Foote board, you can check him out at;  


1. BF 3D

2. bottom mill

3. Deck lam

4. blue

6. Yellow

7. Racing stripe

8. White with green

An Inside Look At How Surf Boards Are Made

We thought we’d give you a step by step behind-the-scenes look at how we build our boards from scratch.

We work directly with our customers to design your new board, we won’t start until all the details of your boards shape, and construction are sorted.

But don’t worry, if your not on Maui, we are accustomed to working remotely with people from all over the world.

1 Design

2.  Next, we CNC mill the bottom of your board.

2 Bottom mill

3.  We custom make a new rocker stick that will help ensure that the entire building process is as accurate as possible.

3 make rocker stick to match board

4.  Next, we check the fit.

4 check fit

5.  The bottom sandwich is vacuumed onto the blank.

5 bottom sandwich

6.  The blank is now milled again for the final deck shape.

6 Final deck CNC mill

7.  The milled deck is finish shaped and all of the inserts are marked for the carbon reinforcements inside the the deck sandwich.

7 Final tune prior to Deck Sandwich

8.  The deck sandwich is now vacuumed down with the rocker stick inside the vacuum bag.

8 Deck Sandwich

9.  The board is finish shaped, insert  locations market again, and then the board is routed using jigs to ensure an accurate installation.

9 Finish shape fully sandwiched board and route for inserts

10.  All of the inserts are installed.

10 install Inserts

11.  The deck lamination is vacuumed on.

11 Deck Lam

12.  Then the bottom lamination is vacuumed on.

12 Bottom Lam

13.  The final sanding coat (or Hot coat) is applied.

13 Hot Coat

14.  The board is now sanded, and spot putty is applied.

14 Sand Hot Coat and Spot puddy

15.  The Spot putty is sanded, the board primed,  a second spot putty applied, and then finish sanded.

15 Sand Spot Puddy and Primer

16.  The final paint is applied.

16 Sand and Paint

17.  The graphics, pads, and texture are applied.

17 graphics pads and texture

18.  Ready to rip!!

18 Test

We hope you found this informative, if you have any questions, drop us a line.

Check out the 12 video’s that show the whole process!

5 Reasons to Choose a Nelson

SUP board constructionDepending on your height, weight and level of skill, you may require a board made specially for you. Most boards today are made in a factory, and are one-size-fits-all. You have to fit the board, rather than the board fitting to you. Nelson Factory is one of the few operations in the world that will make a custom board, constructed just for you.

What makes Nelson  custom boards stand out from the crowd? Here are 5 reasons why:

1. A Perfect Fit

– All of our boards are custom engineered and built around your specific weight, preferences, and location

– CAD designs ensure that you know exactly what you get

– Over 20 years experience working with pros, and people like you to ensure you get the best and most current designs

– Our custom built 3DM CNC machine insures the most accurate board milling

– We can mill 16′ long X 36″ wide, allowing more design flexibility


2. Accelerated Learning

– Having Mark design your next board will help your learning curve in ways not possible from a production board


3. Value

– Utilization of the best materials, ensures years of trouble free sailing, and return on investment when you go to sell


4. Exceptional Service

– Design and construction consultation and attention to detail from start to finish

– Let us build your new board specifically around your needs, from ultra light to supper bomber, we can help you!

– Custom paint and artwork, board colors, graphics, including full board artwork and stickers

– Let Mark help guide you to the right rig, and fins, to optimize your new Nelson custom board


5. The Best!

– You deserve it!  You work hard, so you can play hard, so why not have the best board

– Check out all the Pros we have worked with, more than any other custom shop in the world! Levi SiverKauli Seadi, Josh Angulo, Marcilio “Brawzinho”, Ricardo Campello, Jason Polakow, Björn Dunkerbeck, Matt Pritchard, Kevin Pritchard, Robby Swift, Nik Baker and many more!

– See all the Companies we have worked with from shops to some of the biggest brands in our industry! Mistral, Fanatic, F2, Quatro International, JP Australia, Neil Pryde Maui, Sean Ordonez SOS, Charlie Smith, Timpone, Jimmy Lewis, Angulo and many more!