Your messages on this board are a bit old, but if you're still around, I know a whole family of Kavalar's that live in Michigan. I was married to one of them in the late 80's/Early 90's and still have contact with him.
You may already know about them, but you didn't mention finding Kavalar's in Michigan, so I thought I'd mention them.
My husband was Mark and he has 4 brothers, David, Jeff and twins, Scott and Shawn. Their father is Steve Kavalar. Their uncle is Ray Kavalar and there's a Richard J. Kavalar as well.
I regret I know nothing of their heritage or the name Kavalar, even though it was my own last name for nearly 7 years.