CSF Twin Intercooler Set for 991 Porsche 911 Turbo / S

CSF Twin Intercooler Set for 991 Porsche 911 Turbo / S

CSF Cooling has excitedly unveiled its high-performance intercoolers for the Porsche 991 Turbo & Turbo S models, catering to both the 991.1 & 991.2 variants. These intercoolers first caught the public’s eye at the 2017 SEMA show. For a year after their debut, CSF made the strategic decision to release these exclusively to a handful of the most esteemed Porsche motorsport ECU tuners and vehicle constructors globally. In that duration, these intercoolers, designed for the Porsche 991 Turbo, underwent rigorous testing, logging, and received validation from leading Porsche tuning experts. They have now garnered acclaim as the top choice for performance and value in the aftermarket.

Development

• The journey of crafting CSF’s Porsche 991 Turbo intercoolers commenced with a 3D scanning process, overlaying CSF’s design against the original equipment. It transitioned to scanning the full mounting bracket intercooler cage structure to guarantee a snug and industry-leading fit. A 3D plastic prototype was tested for fitment at their development partner, RD Engineering. During this phase, the prototype’s design was juxtaposed against a prominent competitor’s intercooler system. Equally significant as the cooling system’s R&D, CSF ensures each intercooler set is encased in meticulously cut foam inserts, assuring safe, damage-free global shipping.

Performance

• At a cursory look, the distinction between the OEM’s 80mm core and CSF’s expansive 115mm width is conspicuous. This becomes indispensable for vehicles equipped with performance tunes and bolt-on adjustments. Upgraded turbo systems, in particular, necessitate this enlargement. CSF’s bar/plate core design, being more voluminous, is adept at managing heightened airflow and boost pressures versus the standard intercooler. CSF utilizes 100% TIG-welded cast end tanks, complemented by its efficient bar/plate intercooler core. This stands in contrast to the OEM’s tub/fin core, attached to plastic end tanks, which can succumb to the stresses of high boost or race vibrations.
• One notable feature of CSF’s design is the uniform distribution of airflow throughout the entire intercooler. This design proficiency outshines the original’s, which struggles to direct airflow to the upper and lower sections at the intercooler’s extremities. Further enhancing its efficiency, CSF’s Porsche 991 Turbo intercoolers are treated with an aerospace-grade, nano-particle, heat-dispersing coating, which dissipates heat approximately 35% more effectively than uncoated raw aluminum, whereas the OEM system presents a raw finished core.

Design and Engineering

• CSF prides itself on the extensive research and development that goes into each product. Intent on consistently setting industry benchmarks, CSF meticulously studies not only the OEM designs but also competitor products, aiming to unearth performance enhancement opportunities. This meticulous approach is evident in their decision to invest in precision cast end tanks, optimized through CFD analysis. The outcome? Superior airflow and fitment, trumping CNC machined end tanks that often come with design and production limitations. CSF’s adherence to utilizing all factory mounting points ensures stability and fit. Additionally, CSF stands alone in offering a heat-dispersion coating for its Porsche 991 Turbo intercoolers, providing unparalleled value compared to competitors.

Dyno Testing

• CSF initiated the validation process for their Porsche 991 Turbo Intercoolers using a vehicle modified by GMG Racing, outfitted with standard bolt-on modifications and enhanced with a stage-1 tune from GIAC. A thorough dyno test spanned four days, ensuring consistent ambient air temperatures in a regulated dyno environment. Tests were strategically conducted during specific times—early mornings and afternoons—to manage air density fluctuations. These evaluations comprised multiple real-world scenarios, with the results showcasing a significant boost in performance and superior heat rejection capabilities of the CSF Porsche 991 Turbo Intercoolers.
• During a dyno test with the vehicle in 4th gear at full throttle, the CSF intercoolers’ intake air temperatures (IATs) were approximately 20°F cooler than the IATs recorded from the OEM Porsche intercoolers. Data records further emphasized the superiority of the CSF Porsche 991 Turbo intercoolers, maintaining IATs at a consistent 25 – 40°F cooler than the standard Porsche intercoolers. Initial IATs for the CSF intercoolers were recorded at around 98°F (~37°C). Interestingly, within the first 30 seconds, the IATs decreased by about 10°F, later increasing by a maximum of 15°F, and eventually stabilizing at roughly 103°F (~39°C) for the test’s duration, marking only a 5°F difference from the beginning. In contrast, the IATs of the OEM Porsche intercooler commenced at about 105°F (~40.5°C). These temperatures rapidly escalated, surging by 20°F within the initial 30 seconds. As the IATs continued to rise, nearing a difference of 30°F, the test for the OEM was halted around the 75-second mark due to the concerning increase in IATs, which could potentially hamper vehicle performance.

Dyno Testing Analysis

• Validation processes for these intercoolers were executed on a GMG Racing-modified vehicle equipped with conventional bolt-on modifications and a stage-1 tune from GIAC. Tests were systematically conducted in controlled conditions to ensure consistent results. Among the findings, the CSF intercoolers displayed a consistent 25 – 40°F lower intake air temperature (IAT) than the OEM counterparts.

Performance Testing with Evolution Motorsports

• Quarter mile and half mile races pose a distinct challenge for intercooling systems. When utilizing launch control, a vehicle achieves full boost shortly after starting, pushing heat into the intercoolers. Due to its slow speed initially, there’s minimal cooling airflow through them, making the onset of a 10-15 second high-performance run tough. The intercoolers kept intake temperatures close to ambient levels at 29-30°C for three seconds before they escalated quickly. The temperature surged to 57°C, surpassing the 50°C mark where the EVOMSit software reduces boost to safeguard the engine. The final 1.5 seconds of this trial operated on diminished boost, impacting performance. The trap speed for this test was 134.6mph.
• In contrast, with the CSF Race intercoolers, the rise in intake air temperatures was more moderate, peaking at 38°C by the end of the 10-second trial. The vehicle stayed below the critical limit, preventing any reduction in boost or timing. As a result, it maintained a swifter pace throughout, thanks to the chiller and more compact air intake. The trap speed during this run was 137.4mph, almost 3mph and 0.25 seconds faster than using standard intercoolers. In a half-mile race, the edge provided by these intercoolers is even more pronounced, potentially adding around 7-8mph to a typical Stage 2 vehicle.

Features

• 3D Scanned, CAD Designed, and 3D-printed prototype; tested in collaboration with automotive engineering firm
• CFD tested cast end tanks with several post-machining processes for the absolute best tolerance specifications and maximum airflow distribution throughout the core
• All OEM mounting points are retained with the OEM clip-in hardware design
• Utilizes factory hardware for an OEM-level installation
• OEM style “Quick-Connect” machined fittings for precise fitment, lock, and seal
• Finished with an aerospace-grade, nano-particle, heat dispersion coating that dissipates heat ~35% better than uncoated raw aluminum
• “Drop-in fitment”, no modifications or grinding to metal brackets, etc.
• Individually leak/pressure tested to 120 PSI
• Individually inspected for quality control
• Instruction manual included
• Specifically cut foam protective packaging to ensure damage-free shipment
• 8mm fin height louvered external fin with 6.5mm fin height staggered internal fin – designed to maximize surface area contact and heat dissipation
• Wind tunnel optimized and dyno tested for low pressure drop with best performance
• CSF’s “Ultimate-Boost” high-performance bar / plate core- built in house and pressure tested to 120 PSI
• 4.53-inch thick core compared to OEM’s 3.15-inch core (115mm vs 80mm)
• Increased flow area by 43.75%
• Increased surface area by 70% (8.5m^2 vs. 5.0m^2)

Applications

• 2014 to 2016 Porsche 911 Turbo: 991.1 | 3.8L TT F6
• 2016 to 2019 Porsche 911 Turbo: 991.2 | 3.8L TT F6
• 2014 to 2016 Porsche 911 Turbo S: 991.1 | 3.8L TT F6
• 2016 to 2019 Porsche 911 Turbo S: 991.2 | 3.8L TT F6

Notes

• Requires slight trimming to the plastic intercooler shrouds – instructions included 

About CSF

The Racing & High Performance Division of CSF Inc. is dedicated to designing and producing the world’s most advanced, efficient, and dependable cooling solutions. CSF offers a broad range of state-of-the-art cooling systems, with over 250 distinct applications. These include high-performance all-aluminum direct-fit radiators, intercoolers, and oil coolers, as well as bespoke manufacturing tailored for racecars, power sports, off-road vehicles, marine, and industrial applications. Every cooling solution from CSF is meticulously crafted to ensure optimal engine temperature management, even in the most rigorous driving scenarios. With a legacy spanning over 50 years and more than 40 million cooling units distributed worldwide, CSF is widely regarded as a luminary in the industry.

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