The Mazda 3 Rear Motor Mount 2.0: Back & Better

We here at CorkSport are proud to announce the relaunch of the Mazda 3 Rear Motor Mount.

Yes, you read that correct, this is a re-launch. At CorkSport we push ourselves to design and develop new and interesting products every day, with that, we try new and innovative manufacturing designs and methods in an attempt to create exceptional, competitive, cost-effective products for our loyal customers.

Sometimes those new and innovative manufacturing methods end up not being as awesome as we originally expected. This is just part of the designing and learning process. Let’s get into the details.

The original, let’s call it V1, Mazda3 RMM used a new-to-us manufacturing method of applying the polyurethane to the billet aluminum body called vulcanizing. The billet aluminum body and the steel sleeves are mounted in a fixture then liquid polyurethane was poured into the assembly and cooled until the polyurethane had set to the final hardness.  This process appeared to be very promising; each part was set up identically, it was nearly impossible to have any missing parts not sent to you, and most importantly the polyurethane was adhered to the billet aluminum body and therefore could not fall out.  More on that last bit later.

We moved forward with the manufacturing method and had a few samples made with various polyurethane durometers ranging from 60A to 80A.  After various testing, we determined that 70A was the best compromise of response and NVH (Noise, Vibration, Harshness) experienced by the driver. We continued testing for a few months to verify long-term durability and found no issues.  Hooray! We moved forward with production to get this new great Mazda6 RMM out the door to you.

Unfortunately, it appears that our testing period just wasn’t quite long enough.  Eventually, the polyurethane would fail but fail in a style we had never experienced before.  Long story short, polyurethane has excellent compression strength compared to the tensile strength.  The polyurethane was being pulled/split apart due to the forces of the engine.  

Now we had a few options of how to redesign the Mazda 6 Rear Motor Mount after going through the failure analysis.  

  • We could have simply stuck with the same design and just increased the stiffness of the polyurethane.  Increasing the durometer rating of the poly increases the tensile strength, but this would have resulted in an unsatisfactory driving experience for you which was unacceptable.  
  • The other option was to start from scratch again to create a new design that did not compromise the driving experience or the durability; with challenge comes innovation.

Again we went through many different designs, with the greatest challenge coming in the form of retaining the polyurethane pucks.  Typically the polyurethane pucks are retained by whatever the mount is bolting to, but with the Mazda motor mount, the steel sleeves extend far past the outer edge of the polyurethane pucks.  This leaves the pucks free to slide out of the billet aluminum body and cause a major failure.  

Using the conventional polyurethane puck style, we developed a design that would work, but more than doubled the number of parts needed which increased the chance for something to go wrong and drives up the cost.  This design is shown below:

 

The red arrows show the direction the conventional polyurethane puck would slide out of the body.  The red circles show the puck retention system to hold the washer and pucks in the body.  This retention design required many parts to be successful.

With the cost going through the roof we had to go back to the drawing board. There had to be a better way… and there was.  

The third major iteration shown above solved the problems of the V2 design and got us away from the vulcanized polyurethane of the V1 design.  Things were looking good.  With the V3 design, the polyurethane pucks are pressed into the billet aluminum body.  The pucks have ribs, shown with the red circles that are just large enough to keep the puck in place, but small enough to let the puck be pressed into the body.  

With this, we were able to make some clever designs to the RMM to keep it centered in the engine and chassis brackets on the vehicle.  The smaller diameter puck extends out to the ends of the steel sleeves; this keeps the entire rear motor mount centered.  The large diameter puck retains itself in the body and allows the associated steel sleeve free to slide for easy installation; shown with the red arrows.

Now… does it work? YES! Pretty fantastically, we might add!  

We have had this design on a handful of vehicles, one of those being the CorkSport Mazda 3 Racecar during the SCCA Run-Offs at Indianapolis Speedway.  Other than some dirt and grime, the tested RMM looks great.  

You were probably expecting this blog to be all about the details and reasons you should buy this performance RMM for your Mazda 3, Mazda 6, or CX-5.  All those details can be found on our website, and I invite you to check them out.

What we really want to get across here is this:

First and foremost, we will always do the best we can to take care of you and your car if there is ever an issue or concern with your CorkSport part.  

Second, if you are a driving enthusiast, if you go driving for the sake of just driving, then you need this RMM in your life. It will completely change and improve your driving experience, plain and simple.  

-Barett, CS Engineering

 

Introducing: The CorkSport Performance Polyurethane Exhaust Hanger Kit

The exhaust system on your Mazda is a loved and cherished part of your car’s character and performance.

It emits glorious sounds that keep you entertained and smiling from ear-to-ear, but if you can believe it, is only attached to your Mazda by a few soft rubber hangers.

Yes, your hard earned stainless steel exhaust is ONLY suspended by small pieces of rubber…

Here at CorkSport, we think it’s time that you show your exhaust system some love… it’s time to take the rubber off.

We present to you: the CorkSport Performance Polyurethane Exhaust Hanger kit.

This kit replaces the four rubber exhaust hangers that would otherwise be used to mount and suspend your CorkSport Performance Exhaust System; the two rear hangers on the axleback section and the two mid-pipe hangers.

But why is polyurethane better?

Well there’s a few reasons:

  • First, polyurethane is more durable and heat resistant than rubber so the hangers will perform better for a much longer period of time.
  • Second, and most important, the polyurethane used in the CorkSport Performance Kit uses a stiffer compound compared to the OE. The polyurethane hangers have 75A durometer stiffness vs the OE rubber at as low as 50A durometer. The increased stiffness helps minimize the movement of the exhaust while still providing the necessary flex between the car chassis and the exhaust system.

All-together, this means your performance exhaust system for you Mazda 3, Mazda 6, or Mazda CX-5 will not be able to move around under the car during spirited driving such as back roads, auto-crossing, or whatever motorsport event you prefer.

Keeping your exhaust system in places reduces your chance of damaging your beloved Mazda or the exhaust; it’s a win/win.

-Barett @ CS

PS: In addition to these hangers, we also carry the following other exhaust hanger options:

The First CorkSport Branded Ride Mod + Vote For The CBR Graphics!


For those of you who have forgotten or who did not see the initial post we recently purchased a brand-new 2018 Mazda 3 Hatchback. Dubbed the CorkSport Branded Ride (CBR), we set out to start making it less like your mom’s car and more like something that suits the CorkSport name.

We turned to you all for suggestions and got some great feedback. We heard everything from wide bodykits, “slam it to the ground”, turbos and engine swaps, to easier mods like wheels, coil overs, and a new front lip.

We’re sure you’re anxious to find out where we’ve started: Intake? Exhaust? Springs? Our choice might surprise you.


But before we dig in to the first mod for the CBR, we first want to give you guys an opportunity to do something really fun:

Vote To Pick One of The 4 Graphic Concepts For The CorkSport Branded Ride!

Following up on our introduction to the CBR, our team here has decided to involve you guys in a whole new level of making this car look sick: Body Graphics!

Not only are we asking of your ideas and feedback for the mechanics of the CBR, we want you to decide on the aesthetics too. We want YOU to choose what this things actually looks like.

 
Our design team has developed 4 different concepts for the CBR graphics, and we must admit, they look pretty sweet. The concepts bring in a bunch of different styles, from racing to street, and are sure to make this baby an attention-grabber.

Here’s where you come in: We need you to cast a vote for your favorite concept for the CBR.

A few different ways you can vote:
  1. Repost a pic of your favorite concept with #CorkSport & #CorkSportCBR on social media so we can see your vote. Then, tag a friend and ask them to pick their favorite!
  2. Comment on one of our CBR social media posts for your vote with #CorkSport & #CorkSportCBR.
  3. Leave a comment on this blog post with your vote.
Here’s an example:
“So stoked to get to pick the design of the #CorkSport Branded Ride! My vote is on Concept #3 for sure. – @TagYourFriend, what’s your vote?? #CorksportCBR”

We will gather votes together and whatever concept the CorkSport Community chooses will ultimately be brought to life on the real CBR!


Now, on to the First CBR Mod:

 
We did not want to go crazy right off the bat, so we looked at where the average Mazda 3 owner might start. Maybe a license plate kit, short ram intake? Catback exhaust? Lowering springs? – All good guesses.

We decided to go for a reliability mod that many people may not consider right away: a CorkSport Oil Catch Can kit.

Now, why would we install this right away on a brand new car? It shouldn’t have any issues with engine health. – Well, that’s the exact reason we installed it.

If it doesn’t have any issues right now and the engine is clean and new, then why not keep it that way?
As an engine operates, oil mist, fuel vapor, water vapor, and other gases can pass from the crankcase to the intake using the stock PCV system. Over time, as these gases condense, they form gunk and carbon buildup on valves, piston tops, and other vital engine components. An oil catch can exists to catch all of the oil mist and other vapors before they get back to the intake and dirty all of the nice clean engine components. Additionally, these other gases do not do any favors to the combustion cycle. – Just ask anyone who has emptied one during an oil change; what an OCC collects is pretty nasty.

Now let’s get to the install.

Locating the can itself is a snap, and finds a home in the driver’s side fender well. Routing the hoses is the difficult part, surprisingly, as you have to gain access to some of the factory PCV hose. This means removing the air box, intake tube, and even the starter. Once the factory hose is removed, the new hoses are installed and routed to the OCC.

Finally, we added the ball valve to the bottom of the CorkSport Oil Catch Can, which means next time the CBR needs an oil change we have an easy way to drain the OCC as well.

So what’s next for the CBR? That’s completely up to you!

Help us decide by submitting ideas for what YOU would do if this was your car.
REMINDER: We will give you cred for submitting an idea that we use for the mods. In short: This means Your Name will actually be put on the CorkSport Branded Ride!
Stay Tuned, you’ll be seeing more of the CBR soon.

Remember to cast your vote for the CBR Graphics!

Again, here’s how to vote:
  1. Repost a pic of your favorite concept with #CorkSport & #CorkSportCBR on social media so we can see your vote. Then, tag a friend and ask them to pick their favorite!
  2. Comment on one of our CBR social media posts for your vote with #CorkSport & #CorkSportCBR.
  3. Leave a comment on this blog post with your vote.

Dear Car Clubs: We Want To Hear From You!

Dear Car Guy,

Did you know there are LOTS of Car Guys and Gals out there in the Mazdaspeed world?

From Nator Clubs and Mazda Nova Clubs to Mazdaspeed and Meet Up Clubs, the branding is slightly different for each area and each group, but the heart and soul of the people who get involved stays the same.

Great people, big appetites (for speed and food), awesome tastes in beers and booze, and a genuine care for their fellow club members. I have made sure to attend meets and get to know the nitty gritty center of our Mazda Community, mostly because who doesn’t want to do Car stuff with their Car friends. However, I also do it because it’s an integral part of CorkSport’s vision, to give unprecedented levels of customer support and connection to the Mazda Community.

We ultimately just want to LOVE OUR CUSTOMERS, and I’ll take one for the team and meet you Guys and Gals face to face.

We’ve been to the MidWest Nator meet, the East Coast Nator Meet, and the Boise Mazda Take-over event this past year. We have also hosted our CorkSport Dyno day and given the west coast Mazda community a place to gather as well! Let me just say, it’s been amazing getting to know everyone, and seeing some awesome familiar faces.

The one thing that really stands out for me is the sense of community that is built at the center of all of this. I’ll admit I’m a people person, so of course YOU are my favorite part of working for CorkSport, however, it’s a community like no other, regardless of the title it goes by. The values of the Mazda community stay fairly similar, with mods, install days, track days, meet ups, and expansion of the love we all share for the Mazda Platform.

A group of awesome individuals, getting together, teaching those who don’t know how, and taking are of those who do (and still break down).

There are Groups all over the US (and I’m sure international), that we don’t even know about. It’s my hope that when you read this, you pass me your group pages, club names, social addresses, etc., so that CorkSport can help others in your area connect!

Near and Far, no matter where you are, let CorkSport hear from you!

Until next time, stay safe, stay fast, stay happy my friends!

-Kim @ CorkSport

 

 

Charging for the WIN!

Track Tested CorkSport Approved AXM Parts – Leading the Pack.

The last race weekend I had available before the runoffs turned out to be pretty interesting.

Locally there are very few T4 (touring 4) class cars so I often find myself running with other class cars and this weekend was no exception at Portland International Raceway. I showed up for qualifying on Friday morning with a new part to test and a suspension setup with something I had not tried.

I looked over the entry list the day before, and there read a list of cars you would expect to clobber a Mazda 3 on the track. 3 Porsche 911s, a pair of V8 mustangs, an STL Miata and more.

To make sure I had a clear track for qualifying, I hustled to the pre-grid to make sure I was the first car out. Straight out of the pits, I went flat out to get some distance on the Porsches to be able to push the car for the entire time I was out qualifying. As I watched the lap timer in the Mazda 3, my times kept dropping lap after lap. 6 laps in and I had already bested my fastest lap time at Portland by a second, so I called it quits and pulled in to the pits.

On the way out of the track I grabbed the time sheet to review and see where I placed. A quick review of the sheet showed I had qualified the Mazda 3 in second out of 10 cars and I was in front of 2 of the Porsches.

The start of the race didn’t go that great. Out of all the cars on the track I was in the bottom ½ for horsepower. But I was making up the speed in the corners.

One of the back cars jumped the start a bit and managed to take us 3 wide into a corner which is only good for 2. I was forced to give up some room to one of the Porsches to keep from having contact which put me back to 4th. Several laps into the race one of the Porsches who got ahead of me at the start spun off the track so I was able to move back up a spot while trying to chase down the leader who was running ~1 second a lap faster than I was. The 30 minute mark came pretty quick, and the race ended on a not-so-exciting note of me being in 3rd, and the leaders ~ ½ a lap ahead and all but a few of the rest of the field being lapped.

The big question you all want to ask is: “What were you testing for the 3rd Gen Mazda 3?”

First things first, the changes we made to the Mazda 3:
  • We made an adjustment with the CorkSport rear adjustable swaybar. Being able to make quick adjustments on the rear swaybar bar allows us to soften the suspension to match the alignment changes.
  • We had taken more rear camber out of the back of the car with the CorkSport adjustable camber arms, trying to decrease rear grip (yes you read that right). We have been having problems with front end push (understeer) so we worked on dialing rear grip out of the car.  – We had the CorkSport front camber plates maxed out for camber to the class limits, but it wasn’t enough to offset the rear grip.
  • We originally were running our CorkSport Mazda 3 adjustable shocks on the track but we had to remove them as they are not legal for the Touring 4 class. The adjustable shocks make a world of a difference over what I have to use on the car and I wish we could’ve changed back. Being able to fine tune the Mazda 3 suspension is a great asset for any performance driver.

Now to the fun, what I got to test that was new:

The engineers here at CorkSport have been working on a revised Mazda 3 Rear engine mount for the 3/6/Cx5 over the past few months. The best way we have to extreme test parts is on the track.

Think of the race-testing this way: I am driving full throttle, banging gears, and when I am off the throttle means I am on the brakes, so there is no time for the mount to get any rest. There is the maximum amount of heat, load, and stress in a compressed time line, compared to street driven cars, so if failure is to occur it would be on the track.

At the end of the month, I will be doing a test on a final version of the rear engine mount at the SCCA Runoffs and competing to bring home a National Championship for CorkSport and Mazda.

This brings me to my next point: All of the parts mentioned above have been punished on the track and had zero failures. I have been on the same rear sway bar, rear camber arms, camber plates, and short ram intake, and cat back exhaust since we started racing the car at Daytona in 2015.

You just can’t beat the fact that our CorkSport parts walk the talk when pushed to the extreme, which means they won’t let you down, no matter what you’re doing.

Charge for the WIN!

Derrick