Porsche 911 Turbo (964)
Model year: 1991
Generation: 964
Engine: 3.3 L 6-Cylinder Boxer, 320 hp & 450 Nm (M30)
Gearbox: 5-speed manual
Background:
Due to the great success of our Porsche product line we've slowly started expanding "backwards" into older generations as well. The existing 964 product line was developed in 2016 and only consists of hoses, something we've wanted to change for a while.
A common hurdle with developing performance parts for classic sports cars is that the owners of nice, well-kept examples aren't willing to lend them out for product development+on-track testing. And the cars we're offered to borrow are often heavily modified/tuned, which isn't ideal as a baseline for testing. This leaves us with 2 options, either we buy a car outright to get the project done as soon as possible. Or we focus on other projects until an opportunity arises.
In this case we felt that expanding the 964 product range isn't an urgent matter and decided to go with the latter approach.
A common hurdle with developing performance parts for classic sports cars is that the owners of nice, well-kept examples aren't willing to lend them out for product development+on-track testing. And the cars we're offered to borrow are often heavily modified/tuned, which isn't ideal as a baseline for testing. This leaves us with 2 options, either we buy a car outright to get the project done as soon as possible. Or we focus on other projects until an opportunity arises.
In this case we felt that expanding the 964 product range isn't an urgent matter and decided to go with the latter approach.
Then it happened, just as winter was coming to Sweden, we got access to an original 964 Turbo S intercooler. And to spice things up it happened to be from a 1 of 86 "Leichtbau" models which has an increase of 60 horsepower over the regular Turbo S, while using the same engine.
This was perfect as we could now compare the Turbo S intercooler and the Leichtbau version as a baseline. It was still unclear if the Leichtbau used an improved intercooler or not to achieve its performance gains, only one way to find out if you ask us.
Early Development:
As always, we study the original intercooler to determine if there are any obvious bottlenecks, flaws or opportunities for improvement in general. In the case of the 964 we quickly realised that we wanted to opt for a very stock-ish solution that wouldn't stray too far from the original intercooler. After researching the market and speaking to 964 owners it was clear that maximum performance without sacrificing the original design and classic "feel" was the path to go.
As always, we study the original intercooler to determine if there are any obvious bottlenecks, flaws or opportunities for improvement in general. In the case of the 964 we quickly realised that we wanted to opt for a very stock-ish solution that wouldn't stray too far from the original intercooler. After researching the market and speaking to 964 owners it was clear that maximum performance without sacrificing the original design and classic "feel" was the path to go.
Thankfully the original solution isn't too limiting, the intercooler is quite large and sits in a good location that gets plenty of natural airflow. The bigger issue was the somewhat inconsistent measurements of OEM units, it's clear that quality control and streamlined production methods weren't as common in the hand built Porsches of the 80's compared to today. This meant that we had to consider a margin of error when it comes to fitment, it can't be a 100% rigid design with zero room for adjustment when we're dealing with handbuilt cars.
Development Results:
As this development was solely focused on the intercooler we ended up creating two versions, one "standard" and one MERA edition with an intercooler core from Garrett Motorsport to bring this into our existing lineup of MERA Porche intercoolers. We also ended up going with adjustable brackets to ensure fitment across the somewhat inconsistent range of factory tolerances.
To comment quickly on the MERA vs standard intercooler:
As this development was solely focused on the intercooler we ended up creating two versions, one "standard" and one MERA edition with an intercooler core from Garrett Motorsport to bring this into our existing lineup of MERA Porche intercoolers. We also ended up going with adjustable brackets to ensure fitment across the somewhat inconsistent range of factory tolerances.
To comment quickly on the MERA vs standard intercooler:
The MERA edition is meant to be the absolute peak of what's possible in this form factor. While using the same design and overall dimensions as the standard version, it switches out the core for a high-performance, motorsport-grade Garrett Bar & Plate intercooler core that is 80mm (3 1/8 inches) thick. This allows for better cooling efficiency without sacrificing airflow, and is better suited for highly tuned, modified and track driven cars.
The downside of this is the price, a MERA edition intercooler will never be able to keep the same price point as a standard version. It's meant to be the best performance available without compromising function.
Which is why we also offer the standard version. This is developed to offer very competitive performance, if not best in class, while also staying within a competitive price bracket. We often get asked "which one should I go for?" and the answer is that the standard edition will be more than enough in most cases. The easiest way to summarize this is that the standard version is the one we actively develop and could easily be the only option, and often is, while the MERA edition aims to squeeze out the last few drops of performance with a much more expensive and sophisticated core design.
The downside of this is the price, a MERA edition intercooler will never be able to keep the same price point as a standard version. It's meant to be the best performance available without compromising function.
Which is why we also offer the standard version. This is developed to offer very competitive performance, if not best in class, while also staying within a competitive price bracket. We often get asked "which one should I go for?" and the answer is that the standard edition will be more than enough in most cases. The easiest way to summarize this is that the standard version is the one we actively develop and could easily be the only option, and often is, while the MERA edition aims to squeeze out the last few drops of performance with a much more expensive and sophisticated core design.
Thoughts on this car / platform:
This is one of the oldest cars we've developed products for, so while the general product development process is the same it meant that we had to take other factors into account during the design process. In the end we ended up with an intercooler that stayed true to our goal of OEM looks, with do88 performance. By staying with the OEM concept we can also ensure no functionality is lost and keep the installation process as simple and straight-forward as possible.
In the end this ended up being a great addition to our pre-existing Porsche 964 Turbo range and further expands our MERA lineup as well. We now cover every 911 generation from the 930 all the way up to the current 992. It's always nice to have a fleshed out range for a particular car/brand, this also allows us to better support our specialist dealerships that only focus on one brand of car.
In the end this ended up being a great addition to our pre-existing Porsche 964 Turbo range and further expands our MERA lineup as well. We now cover every 911 generation from the 930 all the way up to the current 992. It's always nice to have a fleshed out range for a particular car/brand, this also allows us to better support our specialist dealerships that only focus on one brand of car.