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CSF’s complete McLaren 4.0L Intercooler Kit has been meticulously perfected through multiple design iterations of extensive performance and fitment testing. Included as part of the kit, is all the necessary hardware and components for a complete plug-and-play, drop-in solution requiring no modifications to install.
CSF’s Most Extensive R&D Process Yet
Initially designed by CSF R&D partner RK Autowerks using state-of-the art 3D scanning and prototyping equipment, we incorporated a massive custom-spec CSF bar/plate air-to-water core that is 68% larger than the OEM unit. Voodoo Autosport was then consulted to further enhance the design for a complete drop-in fit installation that is truly plug-and-play. Lastly, but not least, CSF reached out to the best tuners of the world’s fastest McLarens, M Engineering, to performance test the coolers. Final results: 99% efficiency (vs. OEM 94%) along with lower pressure drop across the cooling system.
Long time R&D partner and high-horsepower BMW engine specialist, RK Autowerks, approached CSF in early 2020 about developing McLaren 720S Intercoolers that they were in the midst of designing.
Once RK Autowerks had fully utilized all of the available space within the engine compartment to maximize the size of the initial intercooler design, CSF then produced a prototype single piece high-performance air-to-water bar/plate intercooler core.
CSF’s single piece bar/plate intercooler core side by side with the OEM intercooler that uses cooling plate technology(CSF’s Core Volume = 420in³ vs. OEM = 250in³ – A massive 68% increase in core volume).
Next step was to cut the prototype inlet and outlet end tanks and water-side end plates from 6061 aluminum bar stock. These tanks were optimized using SOLIDWORKS flow simulation software during development.
Comparison photos showing the massive difference between the CSF prototype intercooler (left) and OEM McLaren intercooler (right). Also highlighting the larger volume/smoother end tanks of the CSF 100% TIG-welded intercooler vs. the weaker brazed/crimped OEM unit (shown pre-welded).
CSF’s Intercooler Kit is also a preventative maintenance upgrade, as the factory cooling system can leak over time at the core-to-tank crimped seam. This can cause serious issues, including anything from mild to catastrophic engine damage or failure.
Voodoo Design & Engineering (VDE)
Owner of Voodoo Design & Engineering, Eric Cheney, has been a long-time industry friend to CSF. Eric’s skillset is extremely unique in the high-performance automotive industry, as he is both an excellent fabricator as well as a motorsports engineer. Being local to CSF as well as in the center of Southern California, a global hot spot for McLaren tuning, Eric was consulted to not only further improve the design into a production-ready kit, but to also handle all fabrication and assembly.
CSF’s second revision prototype intercooler installed on SSR Performance’s 1,122WHP 720S, tuned by M Engineering.
The final piece to the puzzle, and arguably the most important to this project’s development, has been CSF’s new partnership with M Engineering of Southern California – the number one McLaren tuner in the world and holders of numerous McLaren world records.
M Engineering was approached by CSF to not only validate the performance of the intercoolers, but to also take on distribution of the new intercooler kit through their global network of McLaren specialty tuning companies.
The stock intercoolers work phenomenally well and I was hesitant to think they could be outdone after seeing the efficiency of the stock setup. However, the CSF Intercoolers not only had a higher overall efficiency, but less pressure drop at high air mass flow as well. The data can do more justice than I can do in words.
Jon Hebbeln, M Engineering Co-Owner and Engine Calibrator
Below are charts compiled by M Engineering during their extensive dyno testing. The charts show the increased performance benefits of the CSF 720S Intercooler Kit vs. the OEM Intercoolers during 5th gear pulls.
CSF’s High-Performance Bar/Plate Intercooler technology astonished M Engineering during their testing, with an efficiency result of 99% vs. the OEM 94%.
CSF’s core technology is also more resistant to heat soak compared to the OEM plate-type intercooler core. Not only is the core proven to lower IATs, but also maintains a more consistent lower average temperature – this is ideal for achieving optimal performance on vehicles with larger/upgraded turbochargers as well as maintaining maximum efficiency during racing or demanding driving conditions with repeated pulls such as at the drag strip or half mile events.
Performance testing resulted in lower outlet air temperatures from the CSF Intercoolers, showing almost no increase in intake air temperatures during the entire course of the dyno pull (orange line on the CSF graph on the right-hand side shows improved and consistent performance in intake air temperatures).
Not only do the CSF Intercoolers perform better than the OEM, but also decreased the pressure drop at high air mass flow as well. The OEM intercooler system resulted in approximately 1.0psi of pressure drop vs. the improved performance of CSF’s upgraded intercooler kit showing approximately 0.75psi of pressure drop.
After almost one year of development, CSF is proud to release its much anticipated McLaren 4.0L High-Performance Intercooler Kit, allowing McLaren tuners and owners the ability to lower intake air temperatures, maximize turbo efficiency, and increase boost pressure in their pursuit of the fastest speeds in the world.
As these units are all hand made with multiple specialty components, initial quantities are extremely limited.
High-Performance Intercooler Kit (CSF #8186)
Custom-Spec High-Performance CSF Bar/Plate Core Built In-House
68% Increase in Core Volume vs. OEM
Single Core Dual-Pass Design vs. Inefficient Multiple Core Design Found in Competitors Lower Quality/Less Efficient Offerings
Efficiency Tested at 99% by M Engineering vs. OEM 94%
Pressure Tested to 4bar (58psi)
CNC Machined 6061 Aluminum Billet End Tanks Designed and Produced by RK Autowerks
Finished in CSF’s Aerospace-Grade Thermal Dispersion Space Grey Coating for Maximum Heat Transfer Efficiency and OEM+ Aesthetic
Custom Finishes Available – View Possible Options or Please Inquire.
Integrated Dual 1/8-NPT Methanol Injection Bungs Positioned on Outlet Tank for Post-Intercooling Reduction of IATs
Come Pre-Plugged For Vehicles Without Methanol Injection
Can Also Be Used As Sensor Ports
Complete Drop-in Fit Package With No Modifications Required for Installation
Can Be Installed From the Rear Wheel Well Without Removing the Downpipes
Includes Laser-Cut Machined Brackets and Reinforced Silicone Couplers for Throttle Body Connections
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