Steelharp: That same thing drives me insane also; the use of the word Calvary instead of the word Cavalry.
I just bought a Cav15 lower receiver yesterday. I ordered it through my dealer. With the Cav, the lower receiver, the buttstock, the buffer tube, and the pistol grip are all moulded from one piece of plastic (actually it looks like it is two pieces fastened together but all those parts are one single unit unlike a regular aluminum AR). Mine looks clean as can be. There are no bulges in the seam, but there is a small gap on the seam right where the buttplate goes on. My goal in buying this is to put together an extremly light AR15. I am sending KKF a 16" Bushmaster upper which he is going to turn down the barrel to his superlightweight conversion, shorten the barrel and install a muzzle brake so that the whole thing is the minimum legal length plus a smidgon. I haven't assembled the lower yet, let alone shot it, but it looks fine to me. Time will tell, but the guys I have talked to that actually own CAV arms guns seem to like them well enough. I asked SteyrAUG from this board about his and he says it is his faviorite carbine. Cav Arms has a section on the AR15.com industry forum where they will answer your questions directly; they seem like real nice people.