We always relish a new challenge, so after a call from Regal Autosport to see if we could improve on the intercoolers on the 996 Porsche, we decided to start from scratch to see just how good it could be, rather than working with the manufacturers logic of doing just enough.
We started with improving airflow through the intercoolers with the use of enlarged 60mm silicone hoses, and a redesign of the intercooler end tanks. Then with the charge air sorted, we looked at the cooling air that passes over the intercooler. Our testing showed that the original OEM ducting performed brilliantly so satisfied that it was up to the specification needed we thought we should aim to make a true directly replacement kit, by designing the intercoolers to install perfectly with all the OEM mountings. The new coolers are similar in dimension to the OEM units, but are measurably thicker. The real improvement came with a complete re-design of the intercooler core after our preliminary tests proved a bar and plate design to be more thermally efficient in this installation.
