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EVO GT700 Engine Tuning System:  This complete engine tuning system was 100% ground up designed, engineered and manufactured in house.  When we conceived of the idea in late 2002, our goals were set to create the world’s first complete production 700 HP tuning system for the 996TT that was bolt on.  This argues task began with the purchase of a 996TT that was used for the ground up R&D process. Our concept for this power upgrade was to build a safe and reliable power upgrade that would maximize power without having to strengthen the stock internal motor components.  One of the known hurdles was the ability to deliver enough fuel, air and software calibration to balance the system. 

Proper Fuel Delivery: The OEM fuel system with the stock 6 fuel injectors, stock pump and lines have the ability to support about 600-640 HP while operating on pump fuel before being 100% at the mechanical limits.  In order to safely deliver enough fuel for 700+ HP, we knew the OEM components would not work.   

1.   We started with a set of 6 custom fuel injectors that were engineered and manufactured to our specifications. The higher flow rate injectors maintain a high impedance, which are compatible with the OEM electronics and can delivering enough fuel for 800+ HP. These custom injectors though larger in size, properly deliver an idle fuel level that will not cause rich conditions while under low RPM and load. 

2.   Next, although we have enough fuel injector to deliver the required amount to the combustion chamber, the OEM fuel lines from the fuel pump to the fuel rails were too small.  The OEM lines could not support the fuel volume required to maintain a constant fuel supply to the large injectors. Our upgraded braided stainless lines, which are coated with a protective fire jacket, are nearly double the size of the OEM lines.  Our custom fuel lines deliver more than adequate fuel volume to maintain proper OEM 3.8 bar fuel rail pressures while supplying a fuel volume to support 900 HP. 

3.   Finally we built new fuel rails, fuel filter and adapted our upgraded fuel system to a new high volume fuel pump, which sits in the OEM fuel tank.  This method of development/adaptation required many custom machined components as well as many hours of engineering & testing to allow for a 100% OEM type installation with no modifications.

Properly Sized & Designed Turbochargers:  This was a key aspect to the development process where we spared no expenses and were never satisfied until we reached perfection.  This required a tremendous amount of time designing, fabricating, machining, testing, reengineering, rebuilding, retesting, so on and so on.  We spent months testing different sized turbochargers, headers, software calibrations, clutches, intake tubes, wastegates, spark plugs, fuel grades to draw information from and determine the proper components to achieve our goals. In order to reach the 700 HP goal reliably, we realized that certain OEM components had to be reengineered in order to work properly.

1.   OEM Turbos:  The OEM type KKK 16 & 24 turbos are good units for the different power levels they were designed for.  Typically K16 (OEM 996TT turbos) are good for power levels up to 530 HP while K24 (OEM GT2/X50 turbos) can produce up to 630 HP.  The problem with these OEM units besides their power limitations is their size and efficiency. The K24 turbocharger can produce good power but with increased lag over the K16.  We wanted 700+ HP with less turbo lag and “pin you in your seat” power all the way to redline.  This power level could only be achieved with a different brand and custom designed turbocharger.

2.   EVO / Garrett Turbos: Our goal of 700+ HP was achieved with a custom built Garrett GT turbocharger.  The “GT” is the reason all of our 996TT turbo systems that include these custom turbos start with “GT” in front of the power level they produce. The GT turbocharger we developed is a 100% Garrett GT turbocharger bearing cartridge, bearings, compressor wheel, compressor housing and turbine wheel.  We machine and adapt the OEM KKK housings to accept this Garrett GT turbo, which allows for a perfect 100% bolt on fit.   This allows for our customers to choose their own exhaust system based upon their sound preference, provided the exhaust is compatible with the flow rate required to support the power level. Additionally, this maintains a nearly OEM appearance and 100 % OEM fit. Our proprietary GT turbos are designed to have 25% quicker boost response while being capable of producing more than 25% more power compared to a KKK24 turbocharger.  This increased flow and reduced lag makes for a PERFECT combination of increased low end power while delivering tremendous top end power with 1 precision designed turbo.  Most all 996TT turbochargers available in the market place will have sacrifices however we believe that this is the perfect blend of instant boost while maintaining constant air delivery to develop 700 + HP and revving past 7200 RPMS.

Properly Sized Intake and Exhaust:  Intake and exhaust restrictions associated with an engine reduce performance as well as limiting air volume to support increased power levels.  An internal combustion engine is a very finely tuned air pump.  In order to maximize power, intake restriction must be reduced as well as exhaust restriction must be minimized in order to have an efficient and reliable engine. 

3    Intake restriction – (Air Intake Box): We improve the air intake system by reducing restriction with our “internal venturi technology”.  This new technology was engineered utilizing state of the art CAD CAM 3D modeling, CNC machining, computer controlled Superflow airflow testing, rotational molding, injection molding and countless man-hours. This method of development and stringent testing represents the apex of air induction technologies.  Our V-Flow air intake system replaces the OEM air box and installs in the factory location and utilizes the OEM “ram air” fresh air duct for lower air intake temperatures and added power. Our venturi design allows the engine to draw in more air with less restriction, which helps turbo response as well as lower intake temperatures and added power.  Additionally, our V-Flow system incorporates a custom designed low restriction and cotton air filter that has been designed specifically to the airflow requirements of the 996TT engine. All of these components were designed to work together creating a finely tuned intake system.

4    Intake restriction – (Fresh air feed ducts): The OEM fresh air feed ducts that feed air to the inlet side of the turbochargers needed improvements to sustain our power requirements.  The OEM ducts are fine for stock power levels but become exponentially more restrictive as power is increased.  The small diameter OEM ducts reduce airflow and restrict air volume causing increased heat and an overall power restriction. Our custom V-Flow air inlet ducts are increased in size by more than 45% to 70mm in diameter.  Our larger ducts enable the turbochargers to draw in more air for quicker turbo response as well as sustained air volume for power levels beyond 700 HP. Our system is constructed of a cross link polyurethane material for smooth airflow and reduced heat.

5    Exhaust Restriction – (Sport Exhaust / High Flow Catalysts): The OEM exhaust system was designed to be extremely quiet and to work well for stock power levels.  When power is increased especially to 700+ HP, we had to engineer a system that would support the exhaust flow with minimal restriction while maintaining a civilized exhaust tone. We utilized the worlds finest 100 Cell HJS platinum coated catalysts for ultra low restriction while maintaining OBDII compliance.  The exceptional muffler design utilizes an engineered sound chamber with sound canceling characteristics for an outstanding sound with ZERO interior cabin resonance, while maintaining sufficient exhaust flow to support 700+ HP.

6    Exhaust Restriction – (Sport Header System): We engineered a specific pair of 3 into1 headers that matched the efficiency of the exhaust flow from the heads to the turbochargers.  Our proprietary design incorporates slightly larger diameter primary tubes and longer radius/length mandrel bent primary tubes. This low restriction and higher volume header flows into CNC machined pyramid merge collectors with larger diameter and shorter secondary pipes.  This design increases exhaust velocity, which enables the turbochargers to spool up quicker and maintain flow without hindering turbocharger efficiency and boost. 

Strengthened Engine / Transmission Components: once we started making power levels north of 700 hp, we found that some of the OEM, non power making components, were physically strong enough to handle the increased power.  We had to reengineer some of these OEM components to our specifications in order to maintain OEM reliability at our increased power levels.

EVO Silicone & Billet Boost Hose Kit - Our direct replacement silicone boost hose kit will eliminate a common boost problem on the 996TT's.  On most all modified 996TT's the OEM boost hoses will leak and even blow out under acceleration leaving you with a loss in power and even stranded with a car that will not run.  The OEM hoses are made from a rubber material that will deteriorate with a mass produced stamped aluminum end.  This aluminum end does not secure properly into the intercoolers or "Y"-Pipe causing boost leaks and boost hose blowouts.  Our precisely machined billet ends are a perfect tolerance for the most secure fit.  Our silicone is pressure tested to over 100 PSI, which will not burst even under the most extreme conditions.  REAL WORLD TESTED at over 30 PSI and 1000 HP! The EVO silicone & billet hose kit for the 996TT / X50 / GT2 comes as a complete bolt on kit.

EVO Billet Diverter Valves - Our direct replacement diverter valves will eliminate the notorious "Honking" sound commonly heard when the OEM valves have failed.  Our valves will restore lost power and will hold more boost pressure than the stock units for added performance. In addition, they “recover” quicker than the OEM valves, which allows better spool up after shifts. We designed our valves with a 90 degree vacuum port which allows for additional vacuum line clearance and a trouble free installation.  The EVO billet diverter valve for the 996TT / X50 / GT2 comes as a complete kit and carries our exclusive lifetime warranty.

EVO / Sachs Stage 3 Clutch Kit Upgrade - This Stage 3 upgrade was designed as the answer for a high horsepower street / track 996TT.  This custom designed clutch system was developed specifically for this GT700 system.   We had to have an increased clamping force pressure plate engineered to hold the power and torque. We started with a Sachs racing pressure plate and had the clamping force increased by over 600 lbs.  This high clamp force pressure plate combined with our Carbon/Kevlar disk is capable of holding our GT700 power level without slipping.  This system was specifically designed for use with the OEM dual mass flywheel for 100% stock drive-ability and smooth operation. 

Software Tuning:  This final key component to the development of the GT700 was the most difficult and time-consuming tasks, EVOMSit (Intelligent Tuning) Software Flash.  We spent an enormous amount of time to tune the Bosch ME7.8 computer of our GT700 equipped 996TT.  After countless hours of dyno testing on a AWD Mustang, Dynojet 2WD and hours testing the street and track we were able to combine all of the OEM drive-ability characteristics with proprietary calibrations to create the extraordinary power of the GT700.  Our testing of these computer programs lasted over 6 months in various different conditions with different fuel qualities.  We tested our car in normal driving conditions in city driving to wide-open roads in temperatures exceeding 118 degrees Fahrenheit.  We continued our testing on road courses as well as on 1/4 mile drag strips. After compiling data from all of the different conditions, we made some final changes to incorporate a calibration that fit all of them together.  Additionally, our different testing parameters and conditions, allowed us to create specific computer calibrations for specific conditions.  We have available different software calibrations designed for 91 octane fuel as well as a different one for 93 octane.  We offer a high heat calibration designed specifically for extreme conditions like in AZ or other desert climates like in the Middle East. We also offer a race specific calibration designed for 103 octane with increased performance of 20 HP and 40 TQ.  

Since the release of our GT700 upgrade in 2003, we have been successful in establishing a large and diverse client base that are enjoying the rewards and benefits of our stringent R&D and testing process.  We have GT700 cars throughout the world and have gained worldwide recognition with the success of the system.  In 2004, we entered our GT700 equipped 996TT in the High Roller Shootout consisting of 9 most respected tuners / 996TT in the USA.  Our GT700 car was the overall winner of this event, which proved the capabilities of this highly engineered tuning system. At this event, we were able to record a 134 MPH 1/4 mile speed in a 3400-pound car, which is remarkable.