EMC2

If you’re like me and enjoy the satisfaction of a good bit of preventative maintenance, then perhaps you will also understand why (for me at least) the satisfaction of overcoming a fitment challenge and doing it right in the process is even greater

The resultant duct adapter kit that I created for this job (seen in the pics below) is available here: https://emc2design.com/shop-porsche-...ct-adapter-kit

This project was part of a long list of preventative maintenance and mods I’ve been working on which also included installing the center radiator kit on my 2009 997.2 C2 PDK



The 997.1 kit uses exactly the same radiator, radiator housing and hoses as the 997.2 kit, with the only difference between the 2 kits being the ducting needed.
The 997.2 kit is anywhere from $450 - $600 more expensive than the 997.1 kit, even after you purchase the correct center duct for the 997.2 in addition to the 997.1 radiator kit.
I’d seen a few posts of the 997.1 Kit being used on the 997.2 & highlighting the duct alignment and fitment issues, but I wanted to get the parts in my hands to understand how significant the problem was.

Indeed the fitment was way off, but this is exactly the kind of challenge I enjoy

The problem is interference between the required 997.2 center radiator duct, and the original side ducts installed on 997.2 vehicles which do not have the center radiator install from factory.

Vehicles that came from the factory without the center radiator installed, have different side ducts which:

1. are too large and intrude into the space where the center radiator needs to fit
2. do not have the correct shape to smoothly transition air from the center duct to the side ducts

Fortunately the side ducts are very easy to trim, thus dealing with the interference issue.
However this leaves not only an unsightly gap, but also an abrupt step which is not efficient for air flowing from the center duct to the side ducts.







I therefore decided to develop some custom duct adapters that simply slide onto the ends of the center radiator duct, and are then double secured with push pins.

On the passenger side duct I also integrated a mount for the ambient temp sensor so it can simply be relocated from the original duct and snapped into place in the same way & also ensures the sensor is again in the direct air stream and not sitting in an air “pocket”.

I’m very happy with the outcome. The 3rd Rad Kit is a very easy DIY and I’ve already seen temps move from what was previously a very repeatable 225 deg F on a regular run come down to 212 deg F.

I did a complete coolant flush, along with water pump and thermostat replacement at the same time. I will be posting DIY’s on these soon, but in the interim, below are the pics from the install.

OEM Parts Used:

997-044-100-05 (997.1 3rd radiator kit)

997-575-141-07 (997.2 Center Duct for 3rd Radiator installation)

Adapter Kit link - https://emc2design.com/shop-porsche-...ct-adapter-kit

Phrog Phlyer

Great write-up and wonderful pics!!

Tj40

How did you make those - look very well done!

EMC2

@Phrog Phlyer - thank you.

@Tj40 thank you. They are 3D printed parts.

tapcon

Great pics and write up. Visited the web page, and really appreciate seeing a made in the US product with reasonable pricing even more! TY!

PierW

What a great step-by-step. Makes me that much more confident that this is something I could tackle in a weekend. Thanks for putting in the effort for the benefit of the rest of us!!

EMC2

@tapcon - thank you

@PierW - thanks and yes this is really an easy DIY. Those who don't do a full coolant flush at the same time have pre-filled the rad with coolant mix before connecting up, which I think is a good idea.

VT Blue

@EMC2 I could not have said it better than @PierW. I've wanted to attempt this mod before but have hesitated due to all of the posts/issues. May now do this later this fall.

Thanks so much!

Bob

EMC2

Great to hear @VT Blue Happy to help.

myw

as always KILLER JOB!!

Recruiter_Bruno

I've been considering this for a while but my mechanic has warned me against it because I have a 997.2 GT3 front bumper.
On the GT3 the radiator vents out the top.
Any idea on how to make this work in my situation?

Thanks

yvesvidal

Did you cut some slots on the bottom of your front bumper panel, to evacuate the very hot air behind the central radiator?

Yves

DesmoSD

You just need the .2 upper ducting since you already have the GT3 bumper and venting.

99750448981

EMC2

@myw - thanks

My understanding is the GT3 mounting for the center radiator is different. The radiator angle is different to facilitate air venting upwards instead of downwards with the standard bumpers.
I also think the side ducts are isolated from the center ducts for the GT3 config as per the post by @DesmoSD below.

Yes @yvesvidal - thanks for the reminder - I need to add those pics (very easy to do with a Dremel as the cutouts are pre-marked on the inside of the bumper.



Agreed

EMC2

I've had some questions about GTS & Aerokit bumper fitment. EDIT - the kit has been confirmed to fit 97.2 GTS, but still looking for an Aerokit customer to work with on validation.