Porsche 911 Turbo (992) Intercooler Kit

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

Key features

• Lower inlet temperature under the same test conditions: 36°C (48°C). 12°C lower. See diagram under product images.
• 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! See diagram under product images.
• High-quality Bar&Plate core packages of motorsport design from Garrett.
• 3D free-form designed cast end tanks.
• Specially designed carbon fiber air guides.
• Supplied with high-quality silicone hoses and mounting accessories.
• Port for methanol injection (2x 1/8 NPT) in the intercooler's outlet tank.

Background

While previous generations of the Porsche 911 have their intercoolers in their respective rear fenders, with a Y-pipe connecting them before the charge air reaches 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. Looking at it from the outside, this solution appears more rational, but it also places additional demands on us as manufacturers of performance cooling systems. 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!

Garrett Bar&Plate Core

The core packages are of the Bar&Plate type from the renowned Garrett Motorsport and are of the highest quality. Thin, tightly packed cooling fins provide a solid construction that ensures efficient heat transfer. The core package measures a full 105 mm in thickness and is, in our opinion, 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 amount of work involving 3D scanning, CFD analysis, and 3D printing in several rounds 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. This also includes unique hoses that fit these larger connections. 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 of 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.

Performance

Regarding performance, do88's intercooler kit provides a significant reduction in inlet temperature! The graph below 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!

Testing Procedure

First, four runs were made with the OE 992 intercooler installed. Stop, quick part change on site. 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. Cooling is important, but so is flow. After countless hours at the drawing board, refining 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 OE 992 and do88 intercoolers. What you see is what you get – true performance!

*This video shows a Porsche (992) 911 Carrera, some details may differ. See the installation manual below.

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