To Fit: Porsche 911 (997.2 Turbo) 2010 to 2012
Complete Performance Charge Air High Flow Cooling Kit with Inlet Pipes
To Fit: Porsche 911 (997.2 Turbo) 2010 to 2012
This complete package includes Do88's motorsport grade intercooler package with carbon fibre air guides, high flow Y-pipe with all hoses and accessories for installation and the optional high flow inlet hoses.
The intercooler and y-pipe are great products individually but as a team they give great reduction of inlet air temperatures and at the same time they reduce the back pressure of the whole system; this means increased power!
Significant advantages with Do88's Porsche Performance Charge Air High Flow Kit:
About the Intercoolers:
Do88: After our market research in the beginning of our intercooler development for the 997 generation 2 we understood that not many of the upgrade products on the market are really upgrades but more at the same level as the 997.2 standard intercoolers or sometimes even lower. For this reason we realised from the beginning we could not sacrifice anything to keep the cost down, we just had to do the best possible in the space available in the car!
First of all we carried out a lot of investigation and comparisons between different core types and at last really fell for a high density motorsport core which has great cooling efficiency as well as being light weight. With a great core in place we started to refine the end tank design which brought us to a decision to make cast end tanks as we could then control the air flow distribution over the core in a very precise way. This is very important as a good tank design will be beneficial for both pressure drop and cooling efficiency.
To be able to fit an intercooler with appropriate thickness for the job it was also necessary to design a new upper ambient air guide. This was designed in our 3D scanned environment from carbon fibre to ensure perfect fit to the vehicle integrated air guides and our intercooler. To achieve the best air flow distribution over the core we made intercooler end tanks with 70 mm (2 3/4 inch) connections which then made it necessary to designed custom silicone hoses for all positions.
The hoses are 3D designed with airflow in mind where we CFD tested each hose during development to ensure best possible flow rate of all parts! The hoses between turbocharger and intercooler are special silicone hoses that can withstand up to 240°C (464°F) continuous temperature! Another important aspect for cooling performance is to maximise all ambient cooling air available, to optimize this part we include air block rubber seals for all surfaces where the ambient air guides must seal properly.
With the way we have chosen to build our intercoolers the weight increase compared to the OEM ones is relatively small considering the size of our intercooler and that it's completely made of aluminium. Our intercooler weight is 5,85 kg (12,89 lb) per piece and the 997.2 OEM intercooler weights 3,30 kg (7,27 lb) per piece. It might sound like a big weight increase but not when you compare it to similar core sized intercoolers on the market!
About the Y-Pipe:
Do88: At the beginning of the development process of this product we spent a lot of time thinking what would be the preferred way to build a Y-pipe and here is the result of our conclusions and development process! Our pipe has both a very good flow rate and a low weight which is achieved by combining mandrel bent lightweight pipes with a high quality 3D freeform designed cast joint between them. Onto the cast part we then welded CNC-machined connections for bov and breather hoses.
This construction adds a lot of performance but only small amount of extra weight. Do88 Performance Y-pipe weight 1,52 kg (3,35 lb) OEM plastic pipe weight 1,38 kg (3,04 lb) and competitor cast performance pipe weight 2,76kg (6,08 lb)!
The pipes are then finished in a high quality powder coat that makes them look as good as they perform! You can choose between the more discrete semi gloss black and a fresh silver metallic finish.
About the Inlet Pipes:
Do88: It was a real challenge developing new turbo intake hoses for the 997.2 Turbo. The lack of space makes it really difficult to make a set of hoses that outflow the stock OEM plastic pipes. We achieved this and succeeded in maximising the performance but we had to make the small compromise of letting the hoses have no clearance; so they will push or rub in some non-sensitive areas. The hoses are reinforced with stainless steel wire to ensure overall durability and lasting performance.
Our self-developed intake hoses increase air flow; 26% higher than the OEM hoses. We can ensure you the sensation while driving is very different. The improvement in throttle response is immense, making the car feel so much more refined and alert. This upgrade makes it become what it should have been from the start. This is an improvement no test figures can explain, it has to be perceived behind the wheel of a 997 turbo!
Do88: When it comes to performance our big pack gives a great reduction of the intake temperature compared to the OEM 997.2 intercoolers and Y-pipe! See enlarged diagrams where we show data from our AIM racelogger recorded at 5 full throttle accelerations done in an immediate sequence without any cool down between 40-260 km/h (25-162 mph) in a Stage 1 tuned Porsche 997.2 Turbo PDK. In all tests the car was driven in Sport Plus, automatic gear change and AC off. First we made 5 runs with the car equipped with OEM intercooler and y-pipe then we switched to do88 performance intercoolers and y-pipe and drove car for a while, then we made 5 runs exactly the same as with the OEM parts. The temperatures are significant lower with our intercoolers which is visible in the graph!
As well as lower intake temperature our big pack also flows better than the 997.2 original intercoolers! See enlarged image showing the air flow rates at different pressure drops in the graph where we compared our big pack to the original intercooler and Y-pipe in our own Superflow SF-1020 Probench to verify the final result!
From our five in a row full throttle accelerations between 40-260 km/h (25-162 mph) we have very accurate and consistent test data for the range 50-250 km/h (31-155 mph). When analyzing the numbers, we found that in average we cut down the acceleration time for 50-250 km/h (31-155 mph) by 3 seconds compared to the OEM intercooler and y-pipe! No software programming or adaption reset was done in between the tests.