996 Turbo / GT2 Turbo discussion on previous model 2000-2005 Porsche 911 Twin Turbo and 911 GT2.

The Ultimate 996/997 Intercooler Project

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Old Jan 5, 2016 | 02:48 PM
  #16  
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7k? Ouch.

Id rather run less hp.

FWIW. I had no radiator fans in my old car. In August 14 during nasa nationals it was HOT (upper 90's). I ran a TT session, then straight from the track to the dyno, first one up they strapped it down. I was distracted talking to other competitors and didnt know they left it running for the 20 minutes it took while they had technical difficulties with the computer. They ran 3 pulls, within 4 whp (528,527,528) of what it made fresh off a warmup a couple days before(530,532,531). Didnt lose but 1 hp from one pull to the next. Barely got it done for the next session, went straight back out and repeated same mph every lap (164-165). Actually ran my fastest lap of the weekend in that session.


I think .2's are plenty good enough for low 500's to the wheels.
 

Last edited by heavychevy; Jan 5, 2016 at 02:59 PM.
Old Jan 5, 2016 | 02:56 PM
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Originally Posted by pwdrhound
It's already a proven fact that even smaller aerospace intercoolers (like the Marsons used and independently tested by GTR Nick) widely surpass the performance of the 997.2s. Like I said, the .2s are a great bargain but they do have their limitations. And I'm not a fan of limitations...
Oh, I definitely understand that. I guess its just my marketing brain that is trying to figure out how much of a market you will have for coolers that are very much road course focused at that price point (BTW, posted before I saw all the detailed numbers put up).

I cant argue with the numbers you posted but Im more than likely to go with .2/GTRS than these given the cost and that mine is not a heavy track car. Amazing work though.
 
Old Jan 5, 2016 | 03:09 PM
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Originally Posted by heavychevy
7k? Ouch.

Id rather run less hp.

FWIW. I had no radiator fans in my old car. In August 14 during nasa nationals it was HOT (upper 90's). I ran a TT session, then straight from the track to the dyno, first one up they strapped it down. I was distracted talking to other competitors and didnt know they left it running for the 20 minutes it took while they had technical difficulties with the computer. They ran 3 pulls, within 4 whp of what it made fresh off a warmup a couple days before. Didnt lose 1 hp from one pull to the next. Barely got it done for the next session, went straight back out and repeated same mph every lap. Actually ran my fastest lap of the weekend in that session.


I think .2's are plenty good enough for low 500's to the wheels.
Running 500 to the wheels at low elevations buys you a lot of headroom. This is where the .2s work very well. I am at 600 to the wheels and frequently run +5000' elevations which translates to +9000' density altitudes with +100F track temps. Hot/high=thin air=less cooling. Combine that with a car producing 15-20% more power and these conditions overwhelm the .2 ICs where IATs will climb into the 160s and sometimes higher. With VTGs on 997s, it's even worse where I've seen over 200F IATs on a 997TT with just a Cobb tune/exhaust. Under these conditions, the .2s got destroyed in less than 10 track days as the core itself started to leak like a sieve in addition to separation of the end tanks despite being crimped and epoxied when new. Maybe Elite can chime in and post up pics of what his .2s looked like when he removed them. It's entertaining. Again, the .2s are fantastic ICs if you respect their limitations.
 
Old Jan 5, 2016 | 03:18 PM
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Originally Posted by su_maverick
Oh, I definitely understand that. I guess its just my marketing brain that is trying to figure out how much of a market you will have for coolers that are very much road course focused at that price point (BTW, posted before I saw all the detailed numbers put up).

I cant argue with the numbers you posted but Im more than likely to go with .2/GTRS than these given the cost and that mine is not a heavy track car. Amazing work though.
These are not intended for the masses nor is anyone trying to fund their retirement with these. That's understood. These are aimed at a niche market for those guys looking for the best product money can buy. I wanted a solution to a problem and that's why we decided to get these done. If others want a pair, they can get a set. Nothing more, nothing less. A few more of these will probably make their way into the no holds barred track cars and into +$100K 997TT/GT2s rather than mildly tuned $40K 6TTs where even the .2s are often times more that adequate. That's for sure.
 

Last edited by pwdrhound; Jan 6, 2016 at 01:58 AM.
Old Jan 5, 2016 | 05:33 PM
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What I liked most about this data is the definitive proof that a thicker core (identical design/structure) will in fact cool more effectively. The argument of 3/3.5 being adequate over 4.5+ has gone around for years and the data puts a nail in that coffin. Assuming these are out of reach for the average build, running a 4.5 core will offer significant gains over a 3.5 core.
 
Old Jan 5, 2016 | 07:16 PM
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Originally Posted by pwdrhound
Running 500 to the wheels at low elevations buys you a lot of headroom. This is where the .2s work very well. I am at 600 to the wheels and frequently run +5000' elevations which translates to +9000' density altitudes with +100F track temps. Hot/high=thin air=less cooling. Combine that with a car producing 15-20% more power and these conditions overwhelm the .2 ICs where IATs will climb into the 160s and sometimes higher. With VTGs on 997s, it's even worse where I've seen over 200F IATs on a 997TT with just a Cobb tune/exhaust. Under these conditions, the .2s got destroyed in less than 10 track days as the core itself started to leak like a sieve in addition to separation of the end tanks despite being crimped and epoxied when new. Maybe Elite can chime in and post up pics of what his .2s looked like when he removed them. It's entertaining. Again, the .2s are fantastic ICs if you respect their limitations.
pwdhound is correct with my setup. I was a little shocked to see the JB Weld turn brown and actual separate on the hot side of the intercooler (the formula I used was good for 600F at a 10 min duration and rated stable at 550F at 3960 PSI.) I was also surprised when conducting a pressure test on them, they dropped from 30lbs to 0lbs within a couple of seconds.


A few logs were over 200F for intake temps when ambient temps rose above 90F. I log ever run.



Car Dynoed a measly 518whp prior to track season and nothing was changed with the setup or tune afterwards.


Regardless, even though the GT2RS intercoolers perform well, they are not an option for me..
 
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Old Jan 5, 2016 | 07:35 PM
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I assume you are running VTGs, maybe this is a stupid question but would temps be significantly lower with larger turbos, say A28 or 30 series? I also assume boost pressures and turbo eff play a role here.
 
Old Jan 5, 2016 | 08:31 PM
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Old Jan 5, 2016 | 09:49 PM
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Originally Posted by Aktavate
I assume you are running VTGs, maybe this is a stupid question but would temps be significantly lower with larger turbos, say A28 or 30 series? I also assume boost pressures and turbo eff play a role here.


Hey Aktavate,


I am running the 997 stock VTG's. You would be seeing lower temps but, I don't know the difference between the 996 K16 and K24 options and duty load.


I'm sure some of the logging community could contribute to those facts.


I boost at 22.5psi with my current tune.
 
Old Jan 5, 2016 | 11:07 PM
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It would be interesting to see some sort of a comparison between these and the 4.5 SRM already sells. I expect these will perform better but knowing the delta would be interesting.

Intercoolers are REALLY important IMO. It's free HP if done right and lower temps reduce detonation etc. The cooler you can get the air the better and I'm a believer in volume and mass (within reason) to do it. Sean shared with me some of his findings early on with stock intercoolers (awful!) and I'm really happy with his 4.5 on my car. Look forward to data on this and the side scoops, John will you be running a set of those too? Impressive that these are about 4lbs lighter than the SRM 4.5 with heavier duty end tanks. The design of those is damn awesome btw, I looked over a set in August and they're works of art for sure!
 
Old Jan 5, 2016 | 11:24 PM
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BlKMGK, Great note on this.


I'm sure that SRM would have a set point comparison on their existing intercooler offering. This would make sense and provide them the edge of differentiation on product offering vrs. price.


Pwdrhound and John should get together at some point to talk about their ideas with intake and intercoolers. One could only imagine if it was only one person!
 
Old Jan 6, 2016 | 12:44 AM
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Originally Posted by Aktavate
I assume you are running VTGs, maybe this is a stupid question but would temps be significantly lower with larger turbos, say A28 or 30 series? I also assume boost pressures and turbo eff play a role here.
VTGs run much hotter than conventional turbos. When Elite and I run together in the same session and compare logs, I am usually 30-35F cooler in IATs. I run K16/997GT2RS turbos at 600whp at 1.25 bar (18.375psi).
 
Old Jan 6, 2016 | 12:47 AM
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Originally Posted by BLKMGK
It would be interesting to see some sort of a comparison between these and the 4.5 SRM already sells. I expect these will perform better but knowing the delta would be interesting.

Intercoolers are REALLY important IMO. It's free HP if done right and lower temps reduce detonation etc. The cooler you can get the air the better and I'm a believer in volume and mass (within reason) to do it. Sean shared with me some of his findings early on with stock intercoolers (awful!) and I'm really happy with his 4.5 on my car. Look forward to data on this and the side scoops, John will you be running a set of those too? Impressive that these are about 4lbs lighter than the SRM 4.5 with heavier duty end tanks. The design of those is damn awesome btw, I looked over a set in August and they're works of art for sure!
I am going to run the Aerospace coolers without the side scoops first so that I can get a good apples to apples comparison with the 997.2s. I will than add the side scoops while at the track to get a solid comparison of their effectiveness. Track season kicks of late March / early April for us.
 
Old Jan 6, 2016 | 03:29 AM
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Old Jan 6, 2016 | 04:30 AM
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Can I have your old 997.2 intercoolers
 


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