I did a pressure test to see why the clamp is not holding my lower boost hose and noticed the car wouldn't go over 20 PSI using my air compressor.

I quickly noticed my 997.2 intercooler was leaking...took it to my mechanic and the metal that crimps over the plastic end tank is leaking.

I am not sure if I can fix it or not.

I have been running these with my alpha 28 turbos at 1.6 bar...

 

I am going to try to replace under warranty

 

Guess there not really made for "high" boost.

 

The GT2 RS comes with 1.5 bar but I doubt it puts out nearly as much air as my alpha 28s...

 

I thought there were a bunch of guys running the 997.2 IC"s w/ high boost? How about the stock GT2RS running 1.6bar? Perhaps just like any piece of equipment, once more applications start appearing on cars...there is bound to be a failure here & there!

keep us posted.

p.s. I'm in the market for a set of these headers so I hope this is a one rare failure.

 

I suggest you boys with big HP running these intercoolers do a pressure test.

I did not notice a loss of boost while driving and could still achieve peak boost, but I am sure it hurt performance.

I only pressure tested to see why my lower boost hose was coming off.

 

Ben listened to me and I sent him a pressure test kit... he found the problem ... not one he expected... ... its not to say other things did not go bad but this is a interesting find... the only thing that holds the plastic endtank to the core are tabs and a seal... and it was compromised...

 

Yeh unfortunately it's a plastic to metal connection and doesn't have the strength of the welds. I guarantee I would slather 2 tubes of JB weld on there and pressure test again. May just fail somewhere else tho. But that's me...white trash racing rules!!

 

When the end tank leaks it most likely pushed out the rubber seal. Ben go to a local radiator shop and let them repair it. No sweat.. Most likely the root of the problem you have been having for a long time..

 

Tim, I am getting the warrant replaced under the Porsche 2 year parts warranty....many dealerships did not understand that I was trying to warranty a part that was not installed by Porsche lol

The blown intercooler is the driver's side...I have been having the lower boost hose problems with the passenger side, therefore, I do not think the problems are related.

As far as the lower boost hose goes, Markski welded an awesome fitting to my agency fitting (so it fits my agency hose), so I think that should solve the problem.

 

Lower boost hose problem?? Does it fit kind of strangely and needs a little pressure to fit properly? I noticed the same thing on my passenger side. I ended up adding a ziptie under the metal flange and it sealed fine. Held 25psi on the compressor + me wiggling it around for a few mins.

 

Yep, I took a Forge front end that goes inside the end tank since I know they work , cut it... and took the back end of the AP connection and welded then together... that way he can still use his AP hose.. / the forge one is too big in OEM form...

[IMG]

 

Is that a polished down weld or a machined billet polished?

 

polished down... I did it in 20 minutes.. just cut weld.. port inside.. and polish so its pretty lol

 

Welding aluminum is not the same as steel... Aluminum welding does not have good penetration. That means that when you weld you are just placing filler rod on top of the base metal, Unlike steel which will blend the two pieces. By buffing down your weld you weakened your weld.. Looks good though..