CSF by PWR High Performance Porsche 991 GT2 RS Intercooler System

Introducing a Strategic Partnership Between the World’s Two Most Premier Cooling Manufacturers

It wasn’t easy, but it was bound to happen… the professional motorsports pedigree and advanced engineering of PWR, combined with the tier-1 OEM supplier qualifications and global distribution of CSF. After two years of meetings, countless visits by both companies, and endless late-night phone calls and emails to communicate from Los Angeles to Australia, the 1st of what is to be many collaborations is now available.

Introducing the world’s 1st and only high-performance twin intercooler system for the ultra-exclusive Porsche 991 GT2 RS (CSF #8166).

Since the vehicle’s release, the only Porsche 991 GT2 RS intercooler upgrade was not an upgrade, but a band-aid for the stock 1990’s style water spray system which sprays water from a reservoir in the frunk and onto the intercoolers. The band-aid was to install a larger capacity water tank which simply delayed the inevitable running out of water and output to be automatically limited by the factory ECU to try to keep the engine safe. Until you refilled the reservoir again it’s likely your 991 GT2 RS would struggle with charge temps and limited output.

Experts in cooling CSF and PWR have joined operations to deliver a High-Performance Intercooler upgrade for the 991 GT2 RS which eliminates heat soak and lowers charge air temps on stock, tuned, and tracked cars. CSF achieves this by using an F1 performance-grade core which dramatically improves the efficiency of the intercoolers within the same space constraints.

A tremendous amount of engineering, lab testing, and on-track testing by R&D partner BBi Autosport went into making a supercar intercooler even better.

Design & Engineering

Intercooler Core

The OEM tube/fin core contains a single row 7mm tall flat edge tube along with a high-efficiency multi-louvered 7mm tall fin. The CSF/PWR high performance 991 GT2 RS intercooler kit contains a 2-row core featuring 3mm tall rolled tubes with turbulated inner fins manually placed inside each tube to maximize the dissipation of heat from the charge air flowing through the pressure side of the intercooler core. The ambient side 4.85mm tall multi-louvered fin is also the most efficient fin in the high-performance industry globally with performance similar to PWR’s Formula-1 grade race intercooler cores.

  • The rolled tube advantage of the CSF/PWR intercooler creates a rounded edge which allows airflow to travel around the tube face and into the intercooler core for maximum airflow and heat dissipation (Compared to the OEM flat face tube which scatters airflow when contacting the tube face).

On the left, a close-up of the CSF/PWR 2-row rolled tube intercooler core. It features turbulated square inner-fins manually inserted into each tube for maximum surface area contact and heat dissipation into the ambient air. This innovative and advanced design equates to the absolute best performance possible by lowering Intake Air Temperatures along with low pressure drop.

On the right is the internal air passage of the OEM cooler – a very good tube with rolled fin design that is hard to match, let alone beat, by other cooling manufacturers.

(PWR is the cooling supplier to Formula-1, NASCAR, WRC, and MotoGP to name a few of the premier racing series their cooling components can be found in. Not to mention the OEM supplier for hypercars, such as the new Ford GT and Porsche 918. PWR is highly regarded in the performance cooling industry and known to be one of the world’s best cooling system manufacturers.)

Both the OEM intercooler and the CSF/PWR upgraded performance intercooler kit are designed around 87mm thick cores with ~103mm wide side channel end plates. This allows for a true plug-and-play “drop-in fit” installation that requires absolutely no modifications to install, and does not require trimming of the expensive OEM carbon fiber air ducts.

The CSF/PWR intercoolers have been tested and developed every step away along with BBi Autosport and their “Project VMax” Porsche 991 GT2 RS race car.

BBi Autosport has been working on the development of the intercooler system for the GT2 RS. The new system features advanced tube and fin cores, the same as used by motorsport teams and similar to what is found in the “Clubsport” variants of the GT2 RS. This style core has the best properties for taking the heat out of charged air and is incredibly lightweight. The 5-axis machined end tanks guarantee a plug-and-play fit, as a direct upgrade to the factory system.

These intercoolers have undergone rigorous testing through an array of motorsport events as well as hot weather condition testing. The BBi GT2 RS VMax development vehicle has been run through road courses, 1/2 mile races as well as top speed runs – achieving 227mph with the intercoolers handling the heat generated from the upgraded turbochargers. As the vehicle was pushed through the hot canyons of Palm Springs, the performance was not compromised with temperatures kept in control. The GT2 RS now rarely relies on the water injection to keep the intercoolers within the desired range of operation.

Dmitriy Orlov, Head of R&D at BBi Autosport

Hot weather testing in Palm Springs, CA in July 2019 was conducted by BBi Autosport in 111°F (43.89°C) ambient temperatures. Testing results showed, even in these extreme conditions, that Intake Air Temperatures (IATs) never exceeded 125°F (51.67°C) – a delta of approximately 15°F above ambient temperatures. Validating the performance and the ability to eliminate heat soak of the CSF by PWR High-Performance Intercoolers.

BBi Autosport’s “Project VMax” Porsche 991 GT2 RS race car.
Click here to read the full build journal on Rennlist.
BBi Autosport has always had the reputation for building technology leading high performance race cars, including ½ mile and Pikes Peak winning race builds. BBi’s Project VMax” Porsche 991 GT2 RS race car is the fastest GT2 RS in the world reaching a top speed of 226.95mph.
Click here to read more about the creation of the intercoolers and BBi’s GT2 RS on SpeedHunters.

Porsche 991 GT2 RS High-Performance Intercooler Set

CSF #8166
MSRP / MAP: $4995.00 USD

  • Eliminates Heat Soak and Lowers Intake Air Temperatures (IATs) for Maximum Performance in Race Conditions
  • Formula-1 Performance Grade Core by PWR (2-Row Core Featuring Rolled Tubes w/ Inner Fins)
  • CNC Machined Billet End Tanks
  • 100% TIG Welded vs. OEM Style Gasket and Crimped End Tanks for Maximum Durability
  • OEM Style Inlet/Outlet Connections for Precise Fitment with All OEM Components
  • True Plug-and-Play “Drop-in Fit” Installation Requires Absolutely No Modifications (No Need to Trim Expensive OEM Carbon Fiber Air Ducts)
  • R&D and Performance Testing by BBi Autosport on their “Project VMAX”
    GT2 RS
  • Made in the USA at C&R Racing, a PWR Company

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