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Old 09-11-2019, 05:25 PM   #1
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2008 Beaver Contessa Milan Rebuild

Hi Guys. So I picked up this 2008 Beaver Contessa a few months ago. it had a blowout on the drivers side and hit a guardrail. Needless to say it took out the entire drivers side. all the baggage doors gone. front and rear wheel covers, ripped the rear bumper apart, missing half the nose, bent front axle, windshield and the nose piece that covers the generator and hydr pump.
In this photo I had already done some work. swapped out the axle and reconstructed some metal.
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Old 09-11-2019, 05:37 PM   #2
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Then I made a new plug for the nose fender so I could create a fiberglass Mold. That was not easy since I had nothing to go by except the left side. Once I created the mold I used it to make my new fiberglass piece.
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Old 09-11-2019, 05:43 PM   #3
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Oops that is my puppy not the fender. Lol
Here is the new part
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Old 09-11-2019, 05:53 PM   #4
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I also changed out the Pump.
Then began making the plug so I could cast a Mold for the center piece of the nose. I made it out of wood and plaster sanded it smooth, sealed it and began to layup fiberglass over it to make a mold.
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Old 09-11-2019, 06:07 PM   #5
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Below is a photo of the center/upper nose piece attached to the generator slideout.
I also made a new wheel cover making a mold from the passenger side.
I then fabricated all new cargo doors for the side.
I was lucky that they stuck all the pieces of the rear bumper inside so I was able to patch back together what I had and re-attach it to the coach.
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Old 09-11-2019, 06:13 PM   #6
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Wow. You are very ambitious. That is a heck of a project, but the Beaver is a great mh. What is your background? You must have some real mechanical skills.
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Old 09-11-2019, 06:23 PM   #7
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Still lots of work to do.
1. Fabricate a lower piece for the Generator cover
2. Fabricate a new wheel cover for the rear.
3. Fabricate the cover for the rear coolers
4. Fix the smaller cooler in the rear. I think it is for the power steering since there was a leak back there and I have no power steering.
5. locate and install a new windshield
6. locate handles and locks for the cargo doors and install.
7. Fix items in the relay panel. I replaced about 8 relays that were missing/damaged but I also have a few relay connectors that were ripped off the Printed circuit board.
8. figure out how to get the engine to shut down? Somewhere on that thing there must be a solenoid that shut it off when the key is turned to off. this must be one of my damaged relays or wiring but I have no idea???
9. Rewire my slide pump. the old one used a reversible motor and was quite costly to replace. I bought one with dual acting valves to reverse flow.

I am sure I will have lots of questions for you guys. thanks
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Old 09-11-2019, 06:29 PM   #8
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Quote:
Originally Posted by pduggs View Post
Wow. You are very ambitious. That is a heck of a project, but the Beaver is a great mh. What is your background? You must have some real mechanical skills.
Yes it is one huge project. I really have a small amount of mechanic skill. When I was younger I did lift Pickups and swap drive train parts. Did some minor body work and paint in the past.
Was an electronic Tech on a fighter jet many years ago and did construction for years.
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Old 09-11-2019, 09:04 PM   #9
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Amazing job.
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Old 09-11-2019, 09:14 PM   #10
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That's quite a project! Love the way you're creating body panels from scratch, too! Looking forward to your progress.
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Old 09-12-2019, 01:22 AM   #11
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Rock, you have a PM.
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Old 09-12-2019, 10:08 AM   #12
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You are not alone. A couple of threads you may be interested in:
Just purchased wrecked 2004 Camelot PDQ... big project

MountainAire - Back from the Dead
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Old 09-12-2019, 08:05 PM   #13
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thanks for the links.
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Old 09-12-2019, 08:06 PM   #14
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thank you for the info
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Rock, you have a PM.
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