The new/improved Cavalier Connection turbo kit for the 2.4L DOHC is nearly ready for general release. Jigs and mandrel programs are now complete for consistent-quality custom piping; First production piping runs look good; Concurrent installations on ’00 automatic Z24 (one of our R&D cars), ’99 5-speed (by GM mechanic/customer) and ’98 automatic (by professional machinist/customer) all going very well with no snags encountered. Lots of comparing notes on install tips & techniques being rolled into detailed instruction manual with many photos, which is nearing completion. A few minor tweaks to make installation easier (changing to a shorter bolt here or a stud there) and some test-drive & tuning work is all we now lack. The intercooler piping for this kit has been mocked, tested and is now in for jig development/first production run – we anticipate 3-4 weeks before ready for delivery. We’re just down to final decisions on piping finishes – we’re going to ceramic coat all hot piping and probably powder coat all cold piping – just need to decide on colors, etc.
Below are some pics of the production kit installed on our development 2.4L (on engine stand) and on our actual 2.4L daily driver. We should finish the test car installation this week – just had to re-work a down-pipe to factory exhaust system bolt-on adapter for better fitment. Then it’ll get turned over to one of my sons in charge of the fuel enhancement and dyno tuning aspects of our kits.
This kit is a true complete, bolt-on kit – not a DIY kit. Absolutely everything necessary for a one-person, one-weekend installation, using basic hand tools, is included in the kit. The average customer should be driving the car by Monday morning after a weekend install. NO fabrication, trips to the exhaust shop or auto parts store, or trying to source missing components is required. Everything has been custom designed and manufactured to fit both automatic and 5-speed cars with every available option in-tact. No hacking up of the car is necessary and the kit can also be easily de-installed and the returned to original condition if you sell the car down the road. Every claim we make is based on our own hands-on installation on one of our cars, and can be independently validated by one or more installations done by customer(s).
We’ll be releasing more detailed specs on the kit very soon. Just wanted to give you another progress report and let you know that we may be quiet on this board most of the time, but only because we’re working hard on these kits, as well as developing other products not readily available for J-bodies, such as Cometic head gaskets, a line of custom cams, ported heads, etc. If it makes a J-body go faster and isn’t easily obtainable today, you can bet we’re working on it! Thanks - Leo
http://www.cavalierconnection.com/images/img9.jpg
http://www.cavalierconnection.com/images/img10.jpg
http://www.cavalierconnection.com/images/img11.jpg
nice to see your putting alot of work into this !!
as well as going the extra effort into making a very detailed install manual
where is the IAT sensor?
looks like nice work, but the piping i dont like.
As I stated before, I loathe the piping... 2 things I noticed right off the bat:
1 - the bov isn't welded on???
2 - Are you providing plenty of heat wrap to ensure all of the coolant/power steering lines won't melt with that downpipe?
-Chris-
-Sweetness-
-Turbocharged-
Slowly but surely may some day win this race...
i'm a bit of a newb when it comes to some turbo set ups.... but why no intercooler? is the boost low? ( if that matters) is there any downside other than some hp loss not having an intercooler?
thanks
* IAT being addressed - now hanging free, but plan to add as hard-attach in charge-pipe - holding off on that pending results of research on potential tuning products.
* Working on hard-attached BOV as well - looking at a couple of options to keep pricing reasonable.
* Heater hoses, fuel lines, etc. re-routed for down-pipe clearance (instructs tell/show how). Also, all hot piping (including down-pipe) is heat-coated inside and out to reduce heat.
* Basic kit is 5 pounds of boost. Intercooler kit is developed - just waiting on piping manufacturer to complete jig/mandrel program and run first batch (a few weeks out).
Leo
looking good now you just need to finnish the intercooler piping and the rest of the kit and get that thing over my way. i got my fmic and safc so far and gather more stuff.
<img src="http://www.j-body.org/registry/jay32m/personal_pic.jpg">
Relocation - good. That's necessary with the hot side over on that side of the engine....
Maybe some heat wrap just in case too, should be provided. You cannot be too careful with those hoses.
Looks good, glad to see somebody is doing it right.
-Chris-
-Sweetness-
-Turbocharged-
Slowly but surely may some day win this race...
sweetness. What is the cost going to be? Is there potential for higher boost without a intercooler like the setup in the pictures? will the BOV be welded to the pipe? Dont really like the rubber peice. BUt it it works that way good and shaves off some money of the cost I'm all for it.
Regards,
the problem i see with a welded fitting for the BOV is not everyone wants the same BOV , some like it loud and some want a different sound
I'm digging this kit more and more.
No tenemos que vivir asi! Sangre de mis manos! Viva como si usted muera mañana.
<br>
<a href="http://www.azjbo.com">AZJBO!</a>
I'd like to see pics on the manifold.
- 93 mph in the 1/8 mile
Member of J-Body Of Michigan.
Looks good....... Don't forget to post some dyno sheets for every stage you plan to sell. Also some comments about fuel upgrades could be useful too.
Regards,
___________________________
MAKING MY DREAMS A REALITY
Visit my cardomain site !!!
ELIOT. Now.....boosted.
just cur. will that clear stock hood?
Quote:
the problem i see with a welded fitting for the BOV is not everyone wants the same BOV , some like it loud and some want a different sound
very true. also not all bypass valves are welded on even stock turboed cars, yet they still work just as effectively. my buddy's saab has a Forged (brand name) bypass valve with no flange. holds boost and works perfectly at 14lbs. the model shown with the kit looks like a Forged style as well.
the exhaust housing on the turbo is very nice as well as the polished compressor housing.
as far as the intercooler, will a sidemount or font mount be included with the kit?
1991 Eagle Talon TSi-->soon to be sold =(
1989 Chevy Cavalier z24
A few quick answers:
Yes, the piping clears a stock hood with its padding in place - see pic below;
http://www.cavalierconnection.com/images/img7.jpg
We have developed and test installed the 2.4L intercooler kit . . . the mocked-up pipes are now with one of our piping manufacturers for production set-up (build mandrel programs, jigs, etc.). We posted some pics here earlier of the mocked-up piping in VERY rough finish . . . here's a pic of our 2.2L intercooler kit in finished form. The 2.4L kit piping will probably have a similar finish - it doesn't show very well in the picture, but it's a "black chrome" powder coat finish - VERY durable and resistant to scratches, etc. We hope to have production 2.4L IC kits ready for delivery in a few weeks. How do you like this color?? Our thought was that this would match just about any engine compartment color-theme.
http://www.cavalierconnection.com/images/2.2_ic_1.jpg
A new batch of manifolds are on their way to us now (hoping for Friday or Monday delivery). Once here, we'll send them to Jet Hot for coating. We'll post some before and after pics of one soon. Speaking of coating - we're thinking about going to a satin black finish on the hot parts (versus the silver we now use) because we can get an additional 500 degree protection with black - we're debating whether our customers would prefer black and the highest heat protection . . . or silver and a little less protection . . . keep in mind that, when installed, the manifold and down-pipe don't show all that much (like the "cold" piping does) - what do you think would be the preference???
Clearance around the down-pipe has not been an issue for either our install or the two others. We each followed the "relocation of stock components" instructions and were able to easily get fuel lines, water lines, trans lines, cable and wires all out or harms way. I'll try to get some pics to post.
Hope that caught all the questions! Thanks - Leo
How much is your 2.2L intercooler kit?
~2014 New Z under the knife, same heart different body~
______________________
WHITECAVY no more
2012 numbers - 4SPD AUTOMATIC!!
328 HP
306 TQ
manifold , doesnt really matter color wise , so the higher heat the better
the turbo it self silver
$995 - but keep in mind it's specifically built to fit our turbo kit. Pipe to throttle body out of intercooler should work with other set-ups, but pipe out of turbo compressor is bent to fit how turbo mounts to our (tubular) header and may not work if using a log manifold.
WHITECAVY - Here's a shot of the 2.2L intercooler piping installed so you can see how it's configured to fit our turbo kit. (note: this pic shows piping before welds ground down and powder coating - actual finish is as depicted in pic above).
http://www.cavalierconnection.com/images/2.2_ic_2.jpg
Leo
Just a suggestion...... why don't you clock the turbo down ward, and eliminate about 4' feet and two 90 degree bends of tubing...
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This is a pic of my 2200 using the Cavalier Connection header with the turbo clocked downward.
http://home.comcast.net/~adesire/Underhood_drive_Ennis.jpg
275hp & 306tq - 1999 2.2 ohv
13.2 @ 108 mph
-1996 2.4 liter + Turbo + Built motor + Torco + More boost = Lots o' Power
-2000 Mustang GT + 2004 Cobra motor, Whipple 2.3 supercharger,
built rear-end,Dodge Viper spec T56 6 speed, bolt-ons = wheelies at the track!!!!!
yea i would think theres gonna be some lag issues with all that pipe it has to travel thru. Im interested tho with the intercooled 2.4 kit. keep us updated
J-Bo driver once again.......
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Jake wrote:where is the IAT sensor?
looks like nice work, but the piping i dont like.
i'm w/ dumb ass dislike the piping, they lay out of it.
just kiddin jake your not a dumb ass
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Eddie wrote:Jake wrote:where is the IAT sensor?
looks like nice work, but the piping i dont like.
i'm w/ dumb ass dislike the piping, they lay out of it.
just kiddin jake your not a dumb ass
^Drunk post? ^
lol
I would go with the black coating with an option of silver.
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