cALLAWAY Honker
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Race Director
Joined: Jan 2009
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From: Al
cALLAWAY Honker
Just got in a Honker for my 08. Going to install it myself. Was wondering if any of you guys have ever installed one and if you have any tips on avoiding stupid mistakes. Also the standard LS3 does not have an oil cooler,correct? Appreciate any help!
Melting Slicks
Joined: Jul 2007
Posts: 2,027
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From: The Lost Borough, NYC
I installed my CAI myself and it was pretty straight foward. I called callaway for some advice but the directions were pretty good. I am handy with tools but you should be fine if you are handy as well. The only pain was removing the radiator shroud to cut the hole for it. Its the hardest part of the job, but if you go slow you will be fine.
Burning Brakes
Joined: Nov 2004
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From: Livermore CA
Put a thin sheet of plywood or something hard between your shroud and AC condensor when your are cutting the shroud so if you slip or cut too deep you won't cut a leak into your condensor. Also if you have a heat gun, preheat the shroud area where you are going to cut with the box knife and it will cut much much easier. Go slow, measure twice use new sharp blades. Be safe - anticipate where the blade is going to go if it lets go.
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From: Edmond Oklahoma
Put a thin sheet of plywood or something hard between your shroud and AC condensor when your are cutting the shroud so if you slip or cut too deep you won't cut a leak into your condensor. Also if you have a heat gun, preheat the shroud area where you are going to cut with the box knife and it will cut much much easier. Go slow, measure twice use new sharp blades. Be safe - anticipate where the blade is going to go if it lets go.
Installed mine last year. Straight forward install. I pulled my shroud just to get a better cut and easier to pop-rivit the shroud piece on. The shroud is not too difficult to remove but harder to get back on. The plywood thing works fine just a little harder to work on the shroud. The whole operation takes about 2 hours. 
Safety Car
Joined: Aug 2006
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From: Makena, Maui & NM
Installed mine last year. Straight forward install. I pulled my shroud just to get a better cut and easier to pop-rivit the shroud piece on. The shroud is not too difficult to remove but harder to get back on. The plywood thing works fine just a little harder to work on the shroud. The whole operation takes about 2 hours. 
Safety Car
Joined: Sep 2006
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From: Greer, SC
Put a thin sheet of plywood or something hard between your shroud and AC condensor when your are cutting the shroud so if you slip or cut too deep you won't cut a leak into your condensor. Also if you have a heat gun, preheat the shroud area where you are going to cut with the box knife and it will cut much much easier. Go slow, measure twice use new sharp blades. Be safe - anticipate where the blade is going to go if it lets go.
Due to the design and the need to rivet you MUST take the shroud off to install the Honker. I think you may be thinking of the Vararam with the piece of wood between the shroud and the condensor.
Make sure you have a rivet gun before you start the installation. Nothing really difficult about the install except pulling the shroud out. there are 2 "wings" that must be bent inward to get it out. That was the hardest part. Also make sure you have something to catch the oil when you remove the cooler if you have a Z51 M6. If you don't have Z51 or have it and an automatic you won't have to worry about the cooler since there is none.
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From: Monroe Township New Jersey
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Put a thin sheet of plywood or something hard between your shroud and AC condensor when your are cutting the shroud so if you slip or cut too deep you won't cut a leak into your condensor. Also if you have a heat gun, preheat the shroud area where you are going to cut with the box knife and it will cut much much easier. Go slow, measure twice use new sharp blades. Be safe - anticipate where the blade is going to go if it lets go.
Since you already have the Honker ....... the aforementioned is the way to go! Forget the stupid pop-rivit stuff and use a small screw gun and screw it into place from the bottom, then make sure you seal the entire outside edge. It should take you about 30 minutes at the most good luck & enjoy your new found power
Team Owner
Joined: Sep 2006
Posts: 67,022
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From: Beats UD regularly playing 3D chess, and at life
Since you already have the Honker ....... the aforementioned is the way to go! Forget the stupid pop-rivit stuff and use a small screw gun and screw it into place from the bottom, then make sure you seal the entire outside edge. It should take you about 30 minutes at the most good luck & enjoy your new found power
Pop rivet is the way to go as it will not ever loosen.
To clean up the look, use some black RTV around the perimeter of the filter housing in case you overcut the hole.
Last edited by KarlK; Jan 31, 2009 at 06:59 AM.
Thread Starter
Race Director
Joined: Jan 2009
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From: Al
Callaway Honker
Thanks Guys for all the input. Me and a buddy are going to have at it in a couple of hours. I'm going to remove the shroud though to be on the safe side. I'll let you know how it goes.
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From: Edmond Oklahoma
Thread Starter
Race Director
Joined: Jan 2009
Posts: 17,594
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From: Al
Callaway Honker
"Took us about 3 and a half hours but we got it in. Hardest part was getting the shroud in and out. We made a couple of trips to the parts store to get more push pins and a push pin removal tool. That probably took about an hour. It amazes me that it costs as much as it does. Its alot of money for a plastic air box cover and base. Well I guess that goes with owning a 'corvette.
Melting Slicks
Joined: Jul 2007
Posts: 2,027
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From: The Lost Borough, NYC
Due to the design and the need to rivet you MUST take the shroud off to install the Honker. I think you may be thinking of the Vararam with the piece of wood between the shroud and the condensor.
Make sure you have a rivet gun before you start the installation. Nothing really difficult about the install except pulling the shroud out. there are 2 "wings" that must be bent inward to get it out. That was the hardest part. Also make sure you have something to catch the oil when you remove the cooler if you have a Z51 M6. If you don't have Z51 or have it and an automatic you won't have to worry about the cooler since there is none.
Make sure you have a rivet gun before you start the installation. Nothing really difficult about the install except pulling the shroud out. there are 2 "wings" that must be bent inward to get it out. That was the hardest part. Also make sure you have something to catch the oil when you remove the cooler if you have a Z51 M6. If you don't have Z51 or have it and an automatic you won't have to worry about the cooler since there is none.
Race Director
Joined: Aug 2008
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From: Edmond Oklahoma
I was about to say something similar to this... You really cant install the honker without removing the shroud. Its almost next to impossible to rivet the plastic piece to the shroud near the front end of the car. and if you install it without those rivets near the front end it wont be a tight snug fit. Removing the shroud makes it alot easier to cut and work with. Its worth the extra 2 hours of removal time.
Remove the Shroud!
Melting Slicks
Joined: Jul 2007
Posts: 2,027
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From: The Lost Borough, NYC
"Took us about 3 and a half hours but we got it in. Hardest part was getting the shroud in and out. We made a couple of trips to the parts store to get more push pins and a push pin removal tool. That probably took about an hour. It amazes me that it costs as much as it does. Its alot of money for a plastic air box cover and base. Well I guess that goes with owning a 'corvette.
Thread Starter
Race Director
Joined: Jan 2009
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From: Al
Callaway Honker
Finished just before dark. Went in and cooked a couple of steaks and drank a couple more beers. Left to drive home a couple hours later (about 2 miles). Couldn't feel any real difference at 40-45 miles an hour over that short distance. Got it out of the garage the next afternoon and washed and waxed it and put it back in the garage before the bad weather hit. Will drive it this weekend and see if I can tell anything at interstate speeds.
Race Director
Joined: Aug 2008
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From: Edmond Oklahoma
"Took us about 3 and a half hours but we got it in. Hardest part was getting the shroud in and out. We made a couple of trips to the parts store to get more push pins and a push pin removal tool. That probably took about an hour. It amazes me that it costs as much as it does. Its alot of money for a plastic air box cover and base. Well I guess that goes with owning a 'corvette.