Just a quick note on a set of updates that we performed this week to a customers dedicated 996 TT track car. Car was a DD before we had started work on the project in March 2009. We're now in phase 5 of the program for THIS year, and the customer has made great strides in their driving, so keep pushing the development in planned, phased steps, to stay in sync w the drivers needs and desires. The car has been to over 10 DE events this year....and we still have one more to go in December.
For this phase...need to improve the flow from the turbo's thru the IC....so, on go a new set of GMG IC's. Pretty stuff, nice fit, complete kit....worked well.
First pic is of the car at the October DE event (w HOD)


Now the surgery begins
Off w the bumper cover, and the supporting pieces surrounding the IC's...plus a good view of the complete flow from air intake to turbo to IC to the intake plenum....interesting trip for the air to travel


Another view of the cooling air to air interaction of the IC itself


Pic of the new pieces to be inserted, just before transplant to be performed....nice kit....and why would we be doing this...because the new IC flows substantially better than the stock kit....not only a nice performance upgrade, but also all elements add to the completeness of the upgrade, great hoses, perfect connections, the right type of fittings, perfect alignment and fitment into the tight confines...


Here are some shots of the OEM vs the new GMG IC units -

 

More shots of the side by side comparison of the IC units -



And the result when we put all the pieces back together. Nice fit, all the attachments in the right location, tight fitment w the surrounding shrouds to ensure the max flow of air thru the IC


So, like all the improvements made to date, back to the track for the reality testing.... and here is a closing pic of the car at the last event...Turn 6 at Laguna....if you wonder if the BBS motorsport wheels tuck up nicely inside the fenders.....I think so


List of improvements made to the car to date -
- GMG full roll bar, harness bar, shock tower brace
- Set of Sparco Evo 2 race seats, mounts, sliders
- Set of Sparco 6 point harnesses
- BK fire extinguisher
- Porsche Motorsport steering wheel w quick disconnect
- GMG WC sway bar set
- GMG thrust arm bushings, front and rear
- GMG toe link set, front and rear
- GMG dog bone kit
- GMG WC sport springs
- GMG monoball lower control arm bushings
- Brembo conversion from PCCB to steel race rotors
- PFC race pads
- BBS motorsport race wheels, w current set of Toyo R888s (moving to Hoosiers soon)
- Powerchip ECU tune

And now...the new GMG high flow IC set
Off to the track we go....

 

While looking at the picture of the IC in it's mounting bracket, it occurs to me that there is room for a suction fan to be installed under the IC. Is anyone making fans for this application? Seems to me a fan would go a long way in improving airflow across the IC, thereby cooling the intake air more. Cooler is denser, right?

 

2 part answer
(1) The car is a dedicated track car, so, the car will never be at rest, always at speed, and the airflow from the ducts thru the IC and out the side vents is more than sufficient to create the drop in Temp to accomplish the task....for a track car, if we still believed this were an issue, improving the ducting and flow would be the line of attack
(2) IF the car were a DD more, and you were doing a lot of city traffic, but wanted optimum performance from the turbo setup (and hence, since city traffic, we are not getting the optimum flow of air thru the ducts and thru the IC), then the addition of a fan on each IC would be a good approach, an integrated w a thermostat control in the airflow, you could indeed see something improve so as to NOT get heat soak....but, most don't just drive the car in city traffic and do see the flow of outside air thru the IC....if the driving were more city and highway, the fans can actually occlude the flow, which would be the wrong thing to do

 

Thanks for the clarification, makes sense. Although, the intercooler has such a tight configuration of fin work that I'm sure it slows down transiting air, so maybe a powerful fan could still help draw air through the fins. Have you been able to accurately measure the airflow through the IC canal? Not questioning your expertise, just trying to learn.

 

Have not measured...but in another post, of a user in this forum installing another set of IC in the same location, they found that the IC not only improved the flow, but had a significant impact on horsepower on the top end when the heat of the turbo's is at it's max...so, if you want more power, and to lose the heat soak....these are a great set of IC to install
(and obviously, we can sell and provide the GMG set to anyone interested)