Cavalier Connection has been intentionally quiet here lately because we’ve been working our tails off redesigning various aspects of our 2.4L DOHC kit (including custom intercooler piping) -and- some tweaks on our 2.2L (OHV) kit (intercooler piping now completed for that one!) before we tackle putting the finishing touches on our complete Ecotec kit – all of which will fit both automatic and 5-speeds.

While we’re still 3 to 4 weeks out from having all the production custom piping in inventory and ready to ship for the revised 2.4L base and intercooled kits, we thought it might be the right time to give an update on our 2.4L kit.

We bought an automatic ‘00 Z24 with every option for our R&D car to be sure our kit fit around every possible circumstance (automatic, cruise control, fog lights, etc.) WITHOUT having to hack up the car or remove accessories like A/C, windshield washer reservoir, cruise, etc. We also engineered everything such that it is an honest, absolute bolt-on install (NO welding, hacking or fabrication required), using ONLY basic tools the average person owns and that it includes EVERY last nut, bolt, washer, fitting, clamp, connector, pipe, gasket, etc. etc. necessary so it can be installed WITHOUT having to run to the auto-parts store for anything AND we’re putting the finishing touches on a set of instructions that are very comprehensive, complete, step-by-step and full of helpful pictures. Every piece of piping is custom made (mandrel bent and/or welded) for our kit to our specifications and programs or jigs have been produced for every piece to ensure precise repeatable manufacturing. Each piece of piping is also custom bracketed to fit to stock bolts on either the engine (for pieces which must torque with the engine) or chassis.

While we do the install (over and over to find the easiest way and make sure it’s doable without performing unnatural acts), a beta customer, who happens to be a GM dealership mechanic, is doing a concurrent installation on his 5-speed car so we can compare notes and make sure we accommodate any possible differences.

All base kit piping is already in for an initial production run. The custom intercooler cores are in full production mode now and the intercooler piping has been mocked up and will soon be sent to manufacturers for program/jig building and first test runs. We’re on our third iteration of fuel enhancement solution trials because we want to be sure we offer a product providing the best possible combination of performance, cost and practicality – we’re about 30 days away from making that determination. Following all that, we plan to get both the automatic and 5-speed cars to the dyno, then the drag strip for some test & tune work.

We, along with several anxious customers, wish we were a bit further along, but we don’t want to offer the kit until it’s perfected, tested, and inventoried for immediate delivery. We hope you understand. We’re working hard to keep pricing about where it is today, but final pricing still to be determined. We plan to keep complete kits boxed and on the shelf for immediate shipment.

In the interim, here are a few pictures taken during the mock-up phase. Some of this piping will look a little rough because they’re only mock-up pieces from which the manufacturers will build mandrel programs or welding jigs. The “dull silver” charge pipe in one of the photos (for a non-intercooled kit) is an example of a mandrel bent piece (no welds other than the bracket).

Thanks for your patience with us as we continue striving to offer only the best turbo kits for J-bodies with all three engines. – Leo

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Mocked-up Air Intake Tube and first mass-produced unit of mandrel bent Charge Tube

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One of the instruction photos of custom intercooler core installation

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Mocked-up (rough, rattle-can primered) Intercooler Kit piping

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Charge Tube sections of Intercooler Kit mock piping test fit

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Passenger side lower section of Intercooler Kit mock piping (clears horn, frame, bumper cover and fog light)

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Driver’s side lower section of Intercooler Kit mock piping (does not disturb windshield washer reservoir and clears frame, bumper cover and fog light)

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Bumper cover re-installed and hood closed (with heat padding in place) with all piping (including intercooler) and intercooler core installed

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Down-pipe with O2 bung, bolt-on flanges and, of course, a flex-joint.



Formerly Cavalier Connection

Congrats, I hope you guys succeed where Mike failed miserably.

looks good guys keep it up

Yeah looks real good.. Nice job.









~2014 New Z under the knife, same heart different body~
______________________
WHITECAVY no more
2012 numbers - 4SPD AUTOMATIC!!
328 HP
306 TQ

looks like some things improved over mine

the driving lights on the 95-99 models are mounted to the bumper , and they had to remove mine there should be the 4 holes in the bottom of the bumper where the 95-99 lights go , they use the speed clip nuts that clip ino the bumper

when i saw bumper i mean the metal bar , not the cover


also make sure with your down pipe you leave more room where the heater lines run , as it was a problem before

here is a link to my car domain with some pics of the original proto type kit http://www.cardomain.com/memberpage/478869/6

some of them arent the best pics

the 1 thing i always hated was the intake pipe , and the way the turbo sat , i think the turbo needs to sit 180 degrees from where its at now


on 1 of the other pages there is pics of the way the non-intercooled set up , on my motor on a engine stand




i comend you guys on doing good job on the take over of the company

how about some pics of the 2.2ohv piping and kit.

Looks a great bit better than Mike's.

Thanks Eric. The instructions now include (with pics) an easy way to re-rout the 2 heater hoses, the power-brake booster cannister vacuum hose, a hard water line (to overflow reservoir), and re-bracketing the fuel lines - all for either/both more down-pipe clearance or just to make the install MUCH easier. Stock components are used for most of it, but what additional pieces are needed are included with the kit. I literally did this install over and over again just to make sure we made things as easy as possible and that everything was done the RIGHT way! Sometimes just us changing a bolt-length here, or relocating a bracket there made a world of difference in the ease our customers will have installing our kits. (Also, over 30 years experience "wrenching for more horsepower" taught me a trick/technique or two!)

We also take the words "complete" and "bolt-on" literally - so if it's needed to complete the install, it's in the kit . . . and note the little basic Craftsman Mechanic's tool kit in the background of one of the pics . . . if I couldn't complete the install using ONLY the tools out of this kit - we redesigned it until we could! I didn't cheat once by getting into my big chest of mechanic/specialty tools. (There is one special tap required for the no-weld oil return to the pan, but guess what? It's included in the kit!)

We're in this market for the for the long-haul and the only way to succeed will be by offering an honest and high-quality product - which takes a LOT of time, hard work (and an increasingly scary amount of $$) - so that's exactly what we're doing! - Leo

bluejbody97 - A small production run (all already spoken for) of the 2.2 OHV intercooler piping is on it's way from the manufacturer. BUT, one set is for us and we anticipate installing that piping, the revised IC core, writing instructs and shooting pictures sometime next week/weekend. We'll get those posted here the week following Memorial Day weekend. - Leo

by looking at the pics i would guess that the charge piping would interfere with a strut tower bar. that may be something you want to state. as there are so many people here that have them and will bad mouth your company once they get there kit and have a problem like that. otherwise the kit looks great.



Don't steal, the government doesn't like competition

I need to say something about (former Cavalier Connection owner) Mike Clements. Mike put his heart and soul into this company doing his dead-level best to serve this market. He did the best he could with the resources he had at his disposal. He developed some health issues that made it challenging for him to continue driving the company to the next levels and decided it best to sell it. I applaud him for what he accomplished while he owned it. This is a tough niche market segment folks and it's not easy offering high-quality products at affordable prices while making enough money to maintain inventory levels, fund R&D, keep the phone and lights on, pay for the initial costs of jigs, vendor buy-ins, advertising, test cars, insurance, dyno test time, etc, etc, etc - much less afford to pay yourself a dime! We're certainly not there yet (able to pay ourselves anything). It's a big financial risk with no guaranteed return. It's also hard to find the right balance between those who desire the highest levels of power possible without regard to compromises like cost, installation effort, reliability or daily drivability - and - others who prefer the lowest price, easy intallation, turn-key tuning and extreme reliability & durability, even if it means compromising power potential. As far as Mike's approach to things versus ours . . . on any given day, any two gear heads may have different approaches to accomplishing any same objective . . . doesn't make one better than the other - just makes them different. I've spent time in and dealt with people in most U.S. states, Mexico, Canada and even Australia and can assure you Mike is one of the finest people I've had the pleasure of knowing. - Leo

spin1r6 - D'OH!! Nice catch! Thanks! I honestly hadn't even thought about fitting a STB on that car yet! I have a few STBs in the warehouse and will take a look at that ASAP! Thanks again! - Leo

Not too bad guys


<img src="http://registry.gmenthusiast.com/images/carbonfire/redefinedtsisig8qa.jpg">
My 91 Talon TSI On Ebay

I will start off saying that everybody appreciates the work and time and money you're putting into making a true bolt-on kit for the LD9... honestly I have to say bravo to you.

With that said, I opened up the first pic hoping for something fantastic, and all I saw was a complete mess of pipes. Do not get me wrong, functionality is functionality, but I personally know that with my hood with the vent for the ram air, that pipe over the engine will NOT clear. Period. Hell the TB elbow won't clear either.

To be honest, I feel there are much better methods of running the piping, and there is more room in the engine bay than to run it straight over the engine. This, of course, is my own opinion.

Just looking at those pictures, I would have to turn that kit down due to fitment with my hood and basically just the way the pipes are run. But I am one picky bastard which is why I designed my own darn kit.

At the end of the day, what you are doing for the J-market is both fantastic and commendable, and it is 100% appreciated that you are looking at all aspects of the kit so that it may accommodate everybody.

I would have just personally done it differently.

Good luck and I hope eveything turns out as you hope, your company shows a lot of promise.

-Chris-



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Slowly but surely may some day win this race...