CSF’s original Charge-Air-Coolers (Intercoolers) for the McLaren 720S made waves when released in 2021. This system delivered an astonishing 99% thermal efficiency and could be found in the fastest, most powerful McLarens in the world. However, even proven success can be improved. In 2024, CSF went back to the drawing board to address fitment for Spider models and streamline manufacturing amid supply chain challenges.
The result is an all-new, reengineered Charge-Air-Cooler system developed in partnership with CSF’s strategic partner PWR. Compact, more efficient, and now compatible with Spider models, this next-generation system sets a new benchmark in performance cooling for the McLaren 720S, 765LT, GT, plus the new 750S and GTS.
Design & Engineering
This updated system was developed in collaboration with PWR, one of CSF’s strategic manufacturing partners. PWR is known for their motorsports expertise, manufacturing cooling systems for F1, WRC, MotoGP, and more. Together, CSF & PWR have created a high-performance solution tailored for the most demanding McLaren owners, tuners, and race teams.
Both CSF and PWR are Tier-1 OEM-certified cooling manufacturers that specialize in high-performance heat exchangers. These new McLaren Charge-Air-Coolers use advanced core technology, optimized for minimal pressure drop and maximum thermal transfer. Each pair of coolers are made here in the USA with in-house pressure-testing, and quality inspections to meet the stringent demands of McLaren owners. This system delivers unmatched cooling performance for the 4.0L twin-turbo V8 (M840T) found in the 720S, 765LT, 750S, GT, and GTS.
The CSF by PWR Charge-Air-Coolers are handcrafted and professionally tig welded in the USA. Each unit is made with the highest level of craftsmanship and durability that is unmatched anywhere else in the aftermarket.
Key Features:
Advanced core technology with optimized fin design for maximum thermal efficiency
Minimal pressure drop for improved performance under high-boost conditions
Fully TIG-welded by hand in the USA for unmatched quality and durability
100% in-house manufacturing with thorough pressure testing and quality control
Engineered for the GT, GTS, 720S, 765LT, and 750S compatible with both Coupe and Spider models
CSF vs OEM
The OEM McLaren units are very well engineered, offering up to 94% thermal efficiency while handling modest boost increases quite well. This strong baseline performance made developing an upgraded system quite challenging. CSF’s original design (#8186) managed 99% efficiency, but the larger cores caused fitment issues for the Spider models. The new design solves this, delivering exceptional performance in a more compact package that fits all GT, GTS, 720S, 765LT, and 750S variants.
Formula 1 Grade Core
The new CSF coolers feature hand-built bar/plate cores manufactured in PWR’s Tier-1 OEM facility here in the USA (Indianapolis, IN). Each core is produced to aerospace-level tolerances using extremely lightweight and thin materials. This allows for a higher concentration of internal fins, maximizing heat transfer efficiency. The PWR bar/plate core uses 3 times as many fin rows compared to the factory tube & fin core. Bar/plate cores also have a much higher burst pressure rating and can take the stress of boost spikes much better than tube/fin cores.
What makes these cores exceptional isn’t just the materials, but the craftsmanship as well. Building each core is an intensive process requiring expert technicians and precision welders capable of working with cladding as thin as 0.3mm. Only five cores can be built per day by a qualified technician, and welding them requires the highest level of fabrication skill.
Core Construction Highlights:
Air-side & water-side fin thickness: 0.08mm(~50% thinner than conventional cores)
Air-side bars: 5.35mm tallvs. ~7.5mm in standard cores (allows more rows for greater surface area)
Cladding thickness: 0.3mm, enhancing thermal transfer and reducing weight
Air-side Fins Per Inch:28 FPIusing rolled fin geometry (~100% more than typical cores)
Water-side Fins Per Inch:26 FPI(vs. conventional bar/plate core ~18 FPI).
End plates: 1.5mmthick with pocketed 3mm extrusions for max core volume and weld precision
Tank Design & Construction
One of the other shortcomings of the factory coolers is their ability to handle high boost. The factory coolers are an all metal construction with extrusion formed tanks brazed to the cores. This is much stronger than the more common plastic tank with crimped-on gasket seals, but it still leaves room for improvement. The brazed joint is still a weak spot in the system and can burst at higher boost pressures. The new CSF Charge-Air-Coolers fully TIG welded the all aluminum tanks to the cores. This construction method offers the strongest possible coolers that will handle much higher boost pressures than the factory coolers.
The Ultimate Cooling Solution
Whether you need more cooling for your high horsepower build with big turbos or just want to stave off heat soak on track days, the CSF by PWR Charge-Air-Coolers are the cooling solution your McLaren needs.
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