The first and only SLS-printed, configurable Intake Distributor for Porsche 996/997 turbos.
Porsche 996 turbo’s original Intake Distributor is unequal in flow and although 997 turbo’s one is much better (see table below), it’s prone to cracking. If ported or GT3’s cylinder heads much larger intake ports are used, original Intake Distributors are very difficult or impossible to match. The solution is now here, from car enthusiasts to car enthusiasts. CAD drawn, flow bench tested.
These can be ordered in runner diameters for either 996/7 turbo or GT3 cylinder head port sizes. Matching OEM Intake Manifolds need to be used. For 997 turbo’s heads 996 turbo’s intake manifolds and for GT3’s heads their intake manifolds. Both available new and used from various distributors. 42mm inner diameter of 996 turbo’s intake manifolds can be ported to our intake distributor’s runners’ 43mm innner diameter. Even this small porting combined to cylinder heads’ porting will significantly increase flow. For maximum flow increase we suggest using 48mm ID runner diameter with GT3 intake manifold and cylinder heads ported to match and larger valves.
Material is Duraform HST Composite: Datasheet It is also resistant to commonly used fuels, ie gasoline, ethanol and methanol.
Other, but not inferior materials may be used upon customer’s request. Even aluminium or titanium but of course at extra cost.
Airform Intake Distributors will be delivered unpainted. Various automotive paints can be used, like VHT Black Wrinkle Paint in pictures below.
These have been run in a 600 hp 996 turbo for several trackdays in +30C OAT without problems, so durability is no problem.
In addition to runner diameter/port sizing customization these can be ordered with printed “AIRFORM” or without the text as standard or with customer’s own text. As seen in these pictures with text “CTR”. Maximum size is 25 x 200 mm. If no text is ordered, ribs continue all the way across the manifold. Copyrighted words may not be used. Examples: “PORSCHE” or “turbo” in it’s original font.
Acessories’ attachment points are matched with 997 turbo, for 996 turbo special adapter plates are available separately.
If needed, we can make these with threaded towers for sensors and/or extra attachment points. Measurements are of customer’s responsibility and extra cost applies.
Aluminium prototype for RH adapter:
In picture below the engine is seen with 997 turbo’s air tract. The Intake Plenum used with these Airform Intake Distributors is one used with 997 turbos. Either the OEM or some of aftermarket ones. We recommend do88 products as in the picture below, there covered with heat reflective material. The throttle body can be the original 76 mm or larger 82mm from the GT3. Airform Intake Distributors will also clear the taller GT3 Cup heat exhanger widely used in track/racecars.
When our intake distributors are used on 996 turbo engine the oil pressure sensor must be relocated.
The table below is the flow bench comparison between several OEM Intake Distributors and final testing of Airform Intake Distributor with several parts of the intake tract.
All testing was done in suction mode and 28″ H2O, in the picture the very first prototype:
The table contains flow bench test of different 996/996 Intake Distributors. Explanations partly cut out in the table are “Distributor’s runner’s Inside Diameter” and “Distributor’s Volume in cc”. All flow bench testing was done in suction and correct direction of flow, without any trumpets or such @28″ H2O. “CTR” was the prototype/development process name for this AIRFORM Intake Distributor.
RENNLIST discussion forum has a thread about this, LINK.
This product is now available through my WEBSHOP .