CSF McLaren 720S / 765LT / 750S / GT / GTS Charge-Air-Coolers

CSF’s Charge-Air-Coolers (Intercoolers) for McLaren models including the 720S, 765LT, 750S, GT, and GTS represent a pinnacle of engineering excellence in thermal management systems. Originally launched in 2021 with a remarkable 99% thermal efficiency, these intercoolers quickly established themselves as the preferred choice for high-performance McLaren vehicles. Recognizing the evolving demands of McLaren owners and the need for compatibility with Spider variants, CSF collaborated with its strategic partner PWR in 2024 to redesign and refine this system, enhancing both fitment and manufacturing efficiency amid global supply chain challenges.

The outcome is a compact, highly efficient Charge-Air-Cooler system that not only maintains but elevates performance standards. Designed to provide superior cooling for the 4.0L twin-turbo V8 (M840T) engine across multiple McLaren models, this next-generation solution ensures optimal intake air temperatures, improved boost response, and increased reliability under demanding conditions.

Product Details

Design & Engineering

The updated intercooler system is the result of a close partnership between CSF and PWR, a leader in motorsports cooling technology with extensive experience in Formula 1, World Rally Championship, MotoGP, and other elite racing disciplines. Both companies hold Tier-1 OEM certifications and specialize in manufacturing high-performance heat exchangers, ensuring that the product meets stringent automotive and motorsport standards.

Manufactured entirely in the USA, each pair of intercoolers undergoes rigorous in-house pressure testing and quality inspections to guarantee durability and performance. The advanced core technology incorporated into these coolers is optimized to minimize pressure drop while maximizing thermal transfer, delivering unmatched cooling efficiency essential for the high-output McLaren engines.

Each CSF by PWR Charge-Air-Cooler is handcrafted and TIG welded by skilled technicians in the USA, ensuring a level of craftsmanship and structural integrity that surpasses aftermarket competitors. This meticulous fabrication process results in a product that withstands the rigors of high-boost applications and extended track use.

Key Features:

• Advanced core technology with optimized fin design for maximum thermal efficiency
• Minimal pressure drop to preserve engine performance under high-boost conditions
• Fully TIG-welded construction by hand in the USA for superior durability
• 100% in-house manufacturing with comprehensive pressure testing and quality control
• Engineered compatibility with McLaren GT, GTS, 720S, 765LT, and 750S models, including Coupe and Spider variants

CSF vs OEM

The original McLaren intercoolers are well-engineered, achieving up to 94% thermal efficiency and effectively managing moderate boost levels. However, CSF’s initial upgrade (#8186) improved efficiency to 99% but presented fitment challenges for Spider models due to larger core dimensions. The latest generation addresses these limitations by offering a more compact design without compromising performance, providing exceptional cooling across all applicable McLaren models.

Formula 1 Grade Core

The core technology utilized in these intercoolers is derived from Formula 1 standards. Manufactured at PWR’s Tier-1 OEM facility in Indianapolis, IN, the bar/plate cores are produced with aerospace-level precision. The use of lightweight, thin materials enables a higher density of internal fins, which significantly enhances heat transfer efficiency compared to traditional tube and fin cores.

Specifically, the PWR bar/plate core incorporates three times the number of fin rows relative to factory cores, resulting in superior thermal performance. Additionally, these cores exhibit a higher burst pressure rating, allowing them to withstand boost spikes more effectively than conventional designs.

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