Thanks bro

 

Update on my car, dyno'd last December with stock intercoolers at 496 rwhp, dyno'd again today at 512 whp with the 997.2 IC's, no other changes.

 

What brand boost hoses are you running? Any fitment issues clipping into the 997.2 ICs? Thx...

 

Good to know heavychevy,thanks

 

Stock.

 

My $0.02: prodigymb's car is really the "perfect storm" of circumstances that will allow an IC like Forge, AWE, Proto, Switzer, etc. to shine over the 997.2 ICs.

He already has excellent IAT control with the methanol injection. He's pushing a tremendous amount of CFM through the billet Alpha 3076's and supporting mods. He runs high boost, and is not afraid to use it.

On a car like his, no question, a high-quality, higher-flowing aftermarket IC makes a big difference.

The vast majority of 996TTs would be best served (at least, from a cost/benefit ratio) with the 997.2 ICs, IMHO. Not everyone is pushing 8-900 whp... and, IIRC, the good aftermarket ICs cost at least 2-3x more than the 997.2's.

 

Would you mind post the Dyno?

 

I just installed the 997.2 ICs and have to say that Earl's install instructions were spot on. It took me a better part of the day taking my time and doing it right but the results were an OEM like fit. One thing that I did NOT DO is use the zip ties to hold the ducting to the ICs. I wanted a much more durable and OEM like fit and achieved this by simply cutting the eight stock metal clamps in half and then riveting a piece of aluminum (1/16"x0.75"x1.75") to the center of the stock clamps in order to accommodate the thicker cores. An over all length of the clamp set at 98mm works perfectly. I purchased the 1/16"x3/4" aluminum stock at Lowes (Steelworks Aluminum flat 1/16"x3/4"x3' Item #: 216039 | Model #: 11311). They sell it in 3' and 6' lengths for about $5 and then you can cut the 1.75" strips from it. The rivets I used were small 1/8" rivets also purchased at Lowes for a couple of dollars.

Performance wise, the 997.2 coolers seem to work great. I ran 8 x 25-30min hard track sessions with them over the course of two days in 80 degree weather and the car ran just as hard on the first lap and on the last. Overall I'm very happy with the results.

 

The rivets are a nice solution, but what if you have to remove them again?

 

I am not sure why you would want to remove the rivets but if you were so inclined you can simply drill them out just like any normal rivet which takes about 30 seconds. Just to clarify, the extended straps are still removable from the ducting just like OEM. All you are doing with the rivets is making the OEM metal straps longer by riveting the aluminum "extension" to the OEM straps that you cut in two pieces.

 

I have changed my mind on these intercoolers. These intercoolers are great until you run a lot of power through them. I had one 997.2 intercooler leak and replaced under warranty. Last week I was driving and the endtank completely blew apart. I was running 110 octane at ~1.7 bar.

I am done with these intercoolers. Wasted time and money if you plan on going with medium to high power. I have tial alpha 28s BTW.

 

I'm not surprised. The 997.2 intercoolers were not designed to run that much boost.

 

Incorrect...the 997.2 intercoolers were not designed to run that much air through it.

The GT2RS puts out 1.5-6 bar from the factory and uses these intercoolers. However, the turbos do not put out the 48 lb/min that the alpha 28s do.

 

exactly. too much resistance is created in the lower end tank and it blows up or loosens the clips.

was it the lower on that blew up on ya?

 

Thanks for the info Ben, through you and others I think we've found the ballpark limits on these things. I'm currently testing an all aluminum 16 row prototype cooler that retails for not much more than the .2s and provides awesome cooling, stay tuned for a writeup on them!