Porsche 911 Turbo (992) Intercooler kit

A true performance upgrade for the Porsche 911 (992) Turbo / Turbo S!

If you ask us, this is as good as you can make an intercooler kit for this platform. No rock has been left unturned in our quest for maximum performance in any given section of the system. The starting point is the cores from renowned Garrett Motorsport, these are incredibly well-made with thin and stacked fins, exactly according to our specification in the weighing of cooling and airflow. The end tanks are made from thin, cast aluminum to keep the weight down and still utilize airflow. To accommodate the thicker core, we replace the air guides with carbon ducts made from the best quality! And to remove bottlenecks throughout the system, the intercooler connections are made bigger and come along with do88 silicone hoses designed with soft, sweeping bends. We have not made any sacrifice or compromise during this development – behold the results!

Key figures:
– Colder inlet air temperature in the same conditions: 36°C / 96,8 F (48°C / 118,4 F). 12°C / (21,6 F) lower. See diagram under the product pictures.
– More air to your engine, less backpressure and better airflow! Airflow at 0,125 bar / 1,81 psi pressure drop: 799 CFM (740 CFM), 8% higher! See diagram under the product pictures.
– High-density, motorsport-grade Bar&Plate cores from Garrett.
– 3D, freeform-designed cast end tanks.
– Custom designed carbon fiber ambient air guides.
– Comes with high quality silicone hoses and accessories for installation.
– Meth bungs on the intercooler outlet tank (2x 1/8 NPT).

Background:
Earlier versions of the Porsche 911 have their intercoolers inside each rear fender, with a y-pipe uniting them both before the charge air reaches the inlet manifold. The 992 has a different set-up entirely. The intercooler and y-pipe are now combined to a unit that sits beneath the rear wing. The ambient air is pushed via channels from the rear window, into a scoop on the decklid, and onwards through the intercooler core for optimal heat transfer. Looking at the construction from the side, this configuration really makes more sense, but is also more demanding for us a performance cooling manufacturer. To be able to fit a core with greater volume and surface area, we had to develop new carbon ducts to allow the increase in thickness. We are very happy to have taken our carbon production to the next level with this product – the fitment and finish worthy of an icon as the 911!

Cores from Garrett:
The cores are Bar&Plate, made by renowned Garrett Motorsport. Quite frankly, they are as good as they get. Thin and stacked cooling fins give a dense construction, providing very efficient heat transfer. The core measures 105 mm (4”;) and are exactly as thick as you possibly can make them for this application. The air is distributed to the entire core via free form-designed, cast end tanks. Designing these was a significant undertaking that concluded 3D-scanning, CFD-analysis and 3D-printing many times over until we had a finished prototype. We chose, as usual, to use cast end tanks as they allow shapes that CNC-machining cannot replicate, and to us function always conquers form. Maximum airflow supersedes the bling factor! The tanks are made with machined 70 mm (2,75”;) connections to enable high outputs. To pair with these bigger connections, we also include silicone hoses. Both cores are united by a central outlet tank towards the inlet manifold, utilizing machined connections and meth bungs.

Ambient air guides made from carbon:
The air guides are made from vacuum infused, prepreg carbon and all pieces come with fastening grooves for the air channels just like the OE bits. As complex as the shapes are, we still guarantee perfect fitment! They come with proper rubber seals where this is needed to prevent the cooling air to escape pass the core.

Performance:
When it comes down to performance, the do88 intercoolers significantly reduce the intake temperature! In the graph below the difference towards the OE 992 units is presented. The data is collected with an AIM race logger under 4 consecutive runs in an immediate sequence on a closed airstrip. Full throttle accelerations between 50-250 km/h (30-155 mph) carried out in a Porsche 911 Turbo S (757 hp with updated software and exhaust). Hard braking, no cooldown in between, just full pull five times. The rear wing was in its upper position all the time.

The test was conducted in the following manner:
Firstly, 4 runs were made with the car equipped with the 992 OE intercoolers. Stop, fast change of parts to the do88 intercoolers. Shakedown for a few minutes and then five runs made in the exact same way as with the OE parts. The decrease in inlet air temperature is significant, peak delta is 12°C (21,6 F). See diagram under the product pictures.

Cooling is important, and so is airflow. After many hours in the development, refining the end tanks and choosing a core to meet our demand, the result is an intercooler that is much more efficient in terms of heat transfer as well as airflow. Using our in-house flowbench, Superflow SF-1020 Probench, the airflow is verified for both the do88 intercoolers and the OE 992 units. What you see is what you get – true performance!

*This video features a Porsche (992) 911 Carrera, some details might differ. Refer to the installation manual below.