The complete charge air cooling solution for the Porsche 911 (992) Turbo / Turbo S
Bigpack: Intercooler and boost pipes sold as a unit!
In addition to our intercooler kit, we also offer various other products for the Porsche 992. In this bigpack, in addition to the intercoolers themselves, we offer our intercooler pipes and silicone hoses for improved airflow that will last!
If you ask us, this is the best you can get in an intercooler kit for this platform. No stone has been left unturned in our pursuit of maximum performance in every area of the system. The starting point is the cores from the renowned Garrett Motorsport; these are incredibly well-crafted with thin, stacked fins, precisely matching our specifications for cooling and airflow. The end tanks are made of thin die-cast aluminum to keep weight down while still utilizing airflow. To accommodate the thicker core, we replace the air guides with the highest-quality carbon ducts! And to eliminate bottlenecks throughout the system, the intercooler connections have been enlarged and equipped with DO88 silicone hoses designed with smooth, wide bends. We made no sacrifices or compromises during this development—here are the results!
Key figures (vs. OE):
– Cooler inlet air temperature under the same conditions: 36°C / 96.8°F (48°C / 118.4°F). 12°C / (21.6°F) lower.
– More air to your engine, less backpressure, and improved airflow!
– Airflow at 0.125 bar / 1.81 psi pressure drop: 799 CFM (740 CFM), 8% more!
– Garrett’s high-density, race-grade Bar & Plate cores.
– Freeform 3D cast reservoirs.
– Custom-designed carbon fiber ambient air guides.
– Meth plugs on the intercooler outlet reservoir (2 x 1/8 NPT).
– Complete charge hose kit containing powder-coated hoses, high-temp silicone hoses, and premium hose clamps.
Background:
Previous versions of the Porsche 911 had intercoolers inside each rear fender, with a Y-pipe joining them both before the charge air reached the intake manifold. The 992 has a completely different setup. The intercooler and Y-pipe are now combined in a single unit located under the rear wing. Ambient air is forced through channels from the rear window, into an intake on the decklid, and then through the intercooler core for optimal heat transfer. Looking at the construction from the side, this setup actually makes more sense, but it’s also more challenging for us as manufacturers of high-performance cooling systems. To accommodate a core with increased volume and surface area, we had to develop new carbon ducts to accommodate the increased thickness. We’re thrilled to have taken our carbon fiber production to the next level with this product: a fit and finish worthy of an icon like the 911!
Garrett Cores:
The cores are Bar & Plate, made by the renowned Garrett Motorsport. Frankly, they’re the best you could ask for. The thin, stacked cooling fins create a dense structure, providing highly efficient heat transfer. The core measures 105 mm (4″), which is exactly as thick as possible for this application. Air is distributed throughout the core via freeform, cast-end reservoirs. Designing these was a significant undertaking, requiring multiple 3D scanning, CFD analysis, and 3D printing until a finished prototype was achieved. As usual, we chose to use cast-end reservoirs because they allow for shapes that CNC machining cannot replicate, and for us, function always trumps form. Maximum airflow trumps bling! The reservoirs are made with 70 mm (2.75″) machined connections to allow for high yields. To match these larger connections, we also include silicone tubing. Both cores are joined from a central outlet reservoir to the inlet manifold using machined connections and methanol plugs.
Carbon fiber ambient air guides:
The air guides are made of vacuum-infused carbon fiber, and all parts feature mounting grooves for the air channels, just like the OE tips. No matter how complex the shapes, we guarantee a perfect fit! They are equipped with appropriate rubber seals where necessary to prevent cooling air from escaping and passing through the core.
Aluminum tubes:
We also include DO88 charge tubes in the big pack: a distinctive upgrade that replaces the OE tubes. Constructed from 63 mm (2.5″) mandrel-bent aluminum tubing and finished with a premium satin black powder coat, they provide improved airflow and durability. Four silicone hoses are included with the hoses, including the turbo outlet tubes, which are made to high-temperature specifications. The material is rated for a continuous temperature of 240°C (464°F). The hose clamps in this location are “constant tension” type, meaning they will compensate for thermal expansion of the material.
Performance:
When it comes to performance, DO88 intercoolers significantly reduce intake temperature! The graph in the product images shows the difference compared to OE 992 units. Data was collected with an AIM race recorder during four consecutive runs in immediate sequence on a closed airstrip. Full-throttle accelerations between 50-250 km/h (30-155 mph) were performed on a Porsche 911 Turbo S (757 hp). (with updated software and exhaust). Hard braking, no cooling in the middle, only five times at most. The rear wing was always in the upper position.
The test was conducted as follows:
First, four laps were run with the car equipped with the OE 992 intercoolers. Stop, quick swap of the DO88 intercooler components. Shakedown for a few minutes, and then five runs performed exactly as with the OE parts. The decrease in inlet air temperature is significant, the peak delta is 12°C (21.6°F).
Cooling is important, as is airflow. After many hours of development, refining the final tanks, and choosing a core to meet our requirements, the result is a much more efficient intercooler in terms of heat transfer and airflow. Using our in-house flow bench, the Superflow SF-1020 Probench, the airflow is verified for both the DO88 intercoolers and the OE 992 units. What you see is what what you get: real performance!