Big Pack Porsche 911 Turbo (992)

The complete performance package for both high flow and cold air for Porsche 911 (992) Turbo / Turbo S
Bigpack – intercooler and piping sold together!

Key features

• Lower inlet temperature under the same test conditions: 36°C (48°C). 12°C lower.
• More oxygen to your engine, less backpressure, and better flow!
• Airflow at 0.125 bar / 1.81 psi pressure drop: 799 CFM (740 CFM), 8% higher!
• High-quality Bar&Plate core packages of motorsport design from Garrett.
• 3D free-form designed cast end tanks.
• Specially designed carbon fiber air guides.
• Methanol injection ports (2x 1/8 NPT) in the intercooler's outlet tank.
• Powder-coated, mandrel-bent charge pipes with silicone hoses and hose clamps of the highest quality.

Background

While previous generations of the Porsche 911 had their charge air coolers in the respective rear fenders, with a Y-pipe connecting them before the charge air reached the intake, the 992 has a completely different layout. The intercooler and Y-pipe are now a single unit located directly under the rear wing. Air is forced through channels from the rear window down to a scoop, through the core package for maximum heat transfer. From the outside, this solution appears more rational, but it also places additional demands on us as manufacturers of performance coolers. To accommodate a core package with a larger surface area / volume, new air guides are required for it to fit at all. We are pleased that we have been able to elevate our carbon fiber production to the next level with this product – fit and finish worthy of a car like the Porsche 911!

Core Package from Garrett

The core packages are of the Bar&Plate type from the renowned Garrett Motorsport and are of the highest quality. Thin, densely packed cooling fins provide a solid construction that ensures efficient heat transfer. The core package measures a full 105 mm in thickness and, in our opinion, is exactly as thick as it can possibly be. Air is distributed across the entire core package via free-form designed, cast end tanks. An enormous job involving 3D scanning, CFD analysis, and multiple rounds of 3D printing to get everything right. We chose, as before, to use cast end tanks as they often allow for shapes that CNC machining cannot achieve, and form never precedes function for us. Maximum flow is more important than the bling factor! The end tanks come with machined connections that are 2.75”/70mm to further enable high power outputs. Unique hoses that fit these larger connections are also included. The two core packages are joined by a central, cast end tank with a CNC-machined connection to the throttle body and ports for methanol injection.

Carbon Fiber Air Guides

The air guides are made from vacuum-formed prepreg carbon fiber mat, and all pieces have mounting tabs for the air ducts just like the original. The shapes are very complex, but we guarantee a perfect fit! The guides are supplied with sealing strips where required, to seal tightly against the engine compartment and prevent cooling air from bypassing the core packages.

Charge Pipes

Our Bigpack also includes our pipes and hoses – a true upgrade that replaces the original's thin hoses. Made from 63 mm mandrel-bent aluminum pipes, then powder-coated in a tasteful, silk-matte black color, they offer increased flow and better long-term durability. Four silicone hoses are included, of which those on the turbo's outlet are made with a special high-temperature reinforcement that can withstand a continuous temperature of 240°C. The hose clamps in this position are also of the "constant tension" type to accommodate thermal changes in the material.

Performance

Regarding performance, do88's intercooler kit provides a significant reduction in inlet temperature! The graph below the product images shows the difference compared to the 992 Turbo OE intercooler. All data was collected with our AIM racelogger during four consecutive accelerations on an airfield. Full throttle acceleration from 50-250 km/h in a Porsche 911 Turbo S (757hp with new upgrade software and exhaust system). Followed by hard braking, no cooling between runs, just full throttle!

Tests Performed as Follows

First, four runs were made with the OE 992 intercooler installed. Stop, quick on-site parts change. A few minutes of warm-up, and then four runs with the do88 intercooler in exactly the same way as with the OE a few minutes earlier. The temperature drop is striking, a maximum difference of 12°C, see the graph below the product images. Cooling is important, but so is flow. After countless hours at the drawing board, refining and perfecting the end tanks combined with a core package to meet our requirements, we have a result that speaks for itself. With our own Superflow SF-1020 flow bench, we have verified the flow for both the OE 992 and do88 charge air coolers. What you see is what you get – true performance!

OE references: 992145805G, 992145816C, 992145817B, 992145928D, 992145927D