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During development of our high horsepower turbos kits for the 997TT, we experienced excessively high intake air temperatures. Upon close examination of the stock intercoolers, we found they matched the same specs as the 996TT X50/GT2 design, which is suitable to 600hp, but not much beyond that.
Since an OEM option was not available, and our power goals were well north of 700hp, we undertook the task to construct a completely new intercooler system. As with all our intercoolers, a cast end tank was designed in house using sophisticated CAD (Computer Aided Design) and CFD (Computational Fluid Dynamics) software. Once the end tanks were cast by the foundry, they were then machined on our CNC mill, welded to specially designed cores, and then power tested and refined on our chassis dynamometer.
Compared to stock, our cores are 37% larger (422 cubic inches vs 308 cubic inches). In contrast to the stock cores, ours are a high flow bar and plate style and are built to our charge row and fin count specs. These specifications resulted in improved intake temperatures by a massive 55F and improved drop pressure resistance through the core by 1 psi. Considering that extremely little trimming is involved to fit such effective units to the car, this is a huge engineering feat.
