Welcoming Our New Partners of The CorkSport Shop Program!

What is CorkSport Up to?!

We know you’ve been seeing the social media posts calling for US Performance Installation Shops to contact us. So, as a customer, you have likely been reaching out to your local shop and telling them to call in or head to our link in order to get more info!

First off: A big THANK YOU to those who recommended their favorite shops, and to those Shops who have understood what we are about and got started in an awesome community partnership with CorkSport!

We’re excited to experience the support that has been passed along to the community, as well as to other small businesses through these partnerships.

We’re continuing to work with the Mazda Community to build, expand, and grow the number of enthusiasts out there. In doing this, the partnerships we are building will help the ‘newest generation’ of Mazda enthusiasts to get started somewhere. With the help of a local shop, they can learn what they need to know, have a trusted place to take their car, and find themselves inspired by the work they do.

PIC: Mazdas247.com

CorkSport’s Community Partnerships will allow for Mazda Enthusiasts to have a place to go for installation help, questions, concerns, and inspiration on what their car is capable of.

If you know of a Performance Installation Shop near you, or are one yourself; get in contact with CorkSport to see what we’re capable of accomplishing together!

Contact Us by clicking HERE

 

Shout out to the following companies for being the earliest adopters of CorkSport’s Shop Program!

You’ll see below some of these Performance Shops are run by well-known Mazda enthusiasts, which is why we’ve chosen them as trusted community partners!

This is not an exhaustive list of our partners. We are building that list and you will soon be able to see which Shops we are partnered with on our website. This resource will provide you with a quick guide to where to go for installation help in the future!

We are looking forward to what we can build together in our expanded CorkSport family!

CorkSport Community Partnerships: building the Mazda Community, one enthusiast at a time.

Cheers,

Kim Russell,

Corksport Performance

Turbo Kit in Development for 2014+ Mazda 3 & 2013+ Mazda 6

Since 2013 and the loss of the Mazdaspeed 3, Mazda has really left a lot to be desired as far as power goes for its line-up.

Don’t get me wrong, we love Mazda here at CorkSport; the interiors and exteriors are on point, they get great gas mileage, and are exciting to drive. We will always continue pushing and developing the platform that Mazda is kicking out, but let’s be real…we love power.

That brings us back to why I am writing this exciting blog… Sky-G is getting some TURBO LOVE.

©Car & Driver

I’ll admit, we thought long and hard about moving forward with such a large kit. We hoped, we wished, and we dreamed that Mazda would eventually wise up and kick out a GEN3 Mazdaspeed, and we got really excited when we heard about the CX-9 Turbocharged 2.5L engine. Unfortunately Mazda chose not to go down that path; once we found out about that, we decided it was time to pull the trigger on the GEN3 Mazda 3 & 6 Turbo Kit.

Moving forward on a project of this size was not a trivial decision. There were many aspects to consider:

  • Do we make a complete kit or just design and manufacturing difficult components?
  • What is the right power level to shoot for?
  • How will the engine and drivetrain hold up to the increased stress of forced induction?
  • How do we properly tune the engine?

These are all important aspects we had to consider.

Let me lay out some details and choices we made.

The most difficult and time intensive aspect of the kit is designing the physical components that will make up the kit… the entire kit. And yes, we decided that a 100% complete kit was the only way to make this a great setup, so that exactly what we intend to provide.

A complete kit needs to include everything from the air filter to the downpipe, and everything in-between. This includes the intake system, turbocharger, intercooler piping, intercooler, exhaust manifold, downpipe, and all the necessary silicone couplers, hardware, and wiring extensions.

This will be the most complete turbo kit you can purchase for the 2.5L SkyActiv-G powertrain.

Mazda-3-Turbo-Kit-CAD-Assembly

Right behind developing all the components for the kit comes the tuning. We are working with Versatune to develop the software to control the 2.5L Sky-G engine with forced induction. This portion of the project will be kicked into high gear in the near future once all functional prototypes are on our test car and strapped to the dyno.

Lastly, some thoughts to consider:

Will the engine take the added power?

How much will it hold till it pops?

Time will tell on those questions, but we do have some stuff in the works that will help. However, just spit-balling here, something around 280-300whp would be a lot of fun in the Mazda 3 and Mazda 6.

Stay tuned as this project evolves through testing and development in the coming months.

What are your thoughts on this new project? Questions?

Leave them in the comments section, we would love to hear from you.

I have only skimmed the surface of this project and I could easily write pages and pages if time allowed.

-Barett @ CS

Get Ready for Boise’s 2017 Mazda Takeover Event

Another year, another weekend of Mazda community love. Here’s a rundown of 2016’s Mazda Takeover Event in Boise to prepare for 2017.

Last year, Barrett and I got the chance to head to Boise, Idaho, for a great Mazda Takeover event that my good friend Keith Eggert put together. People from Utah, Washington, and northern Idaho all made the trip for a fun weekend full of racecars, beer, and good laughs. We met some new people and reconnected with friends that we hadn’t seen in awhile. It was a big event made even better by securing a few shops so we could do some fun things besides racing.

This Thursday, we’re heading back to Boise for another weekend of good times. But before we go, let’s reflect on last year’s event.

The 2017 Mazda Takeover event in Boise, Idaho, is a great Mazda community event.
It’s always a good time when the Mazda community gets together.

Dyno Day

Everyone who wanted to dyno their car had the opportunity to do so last year, which made for an incredible day. Almost all of the cars that attended Dyno Day were fully bolted and tuned on E85, so you can imagine we had a lot of quick Mazdaspeeds in attendance.

A few notable results: Cody Allington from Utah made right at 500whp with his HTA turbo and port injection. Next up was my car strapped with the CS turbo and meth coming in at 400whp on the stock block. There were plenty of other Speeds right around 320whp. The smell of E85 and meth definitely told us we were in the right place!

Drags

Once we were done with the dyno, most of us hung out and prepared some cars to run in the 1320. Cody needed to install a cut-off switch, because he had relocated his battery from the engine bay to the hatch of the car. Once we had that all figured out, it was time to head to the track.

Over 40 Mazdaspeeds attended the Mazda Takeover in Boise, Idaho, last year.
That’s a lot of Mazdaspeeds.

We had about 40 Mazdaspeeds show up to the track — the biggest turnout I have ever seen.  I remember thinking this is what the Mazda community is all about: a bunch of friends getting together to have a genuinely good time. That’s something I think we forget about from time to time. I realize there’s a lot of competition out there, but at the end of the day, we’re all in this together.

That race night was great because I got to see a bunch of Mazdas ripping down the track. And, I also got to see the smiles that came with a fun night among a great community.

This year's Mazda Takeover in Boise promises to be bigger and better than the amazing event in 2016.
Boise, here we come.

We’re going to be in attendance again at the Mazda Takeover this year in hopes that the event is even bigger and produces an even larger turnout. The plan is the same as last year. But, this time around, the boys from CorkSport have more lead time so we can take more time off than just the weekend. It’s going to be a amazing!

We are very excited to see what happens this year and look forward to hanging out with 40+ Mazdaspeed people. I highly encourage anyone that is within driving distance of Boise to check out this meetup. At its current rate, this takeover event is turning into the largest on the West Coast. The meetup begins on June 8, and I’d really like to see some fresh faces there!

If you have any questions, please feel free to shoot me (Luke McCarvel) a Facebook message.

Cheers,

Luke

Why You Need Injector Seals for your Mazdaspeed, Part 2

This post is part 2 of a 2-part series on the importance of injector seals. If you’re just now discovering this post, be sure to tune in to part 1 before continuing here.

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Like the title says, you need injector seals for your MZR! Here’s why.

When Mazda designs a part, they design it with the “typical” customer and OEM power in mind – not the power hungry, boost craving driver.  Yeah, I’m talking about you and you know it – and we have just the thing to keep you and your MZR in check.  As you add more fuel and more boost, the weakest link is eventually going to give. That link is the OEM injector seals.

Three Reasons You Need Injector Seals For Your Mazdaspeed

  1. Reliability is sacrificed using the OEM seals.
  2. Leaking seals causes loss of power.
  3. Inconsistent performance is caused by leaks.

So, if you are just tuning in to our blog, then shame on you, go read part one like everyone else! With that, let’s dive into the design of the seal and how it works.

We put 500 hard miles on the Speed3 and here are the results.  500 miles may not sound like a lot, but the company owned MS3 does not live the normal life. It spends most of its time on the dyno testing new products pull after pull, may have hit 35psi, and when it does hit the streets, it’s driven by an employee searching for the governor speed.  I think we can all agree that the 500 miles was a fair amount of abuse to put the injector seals. Plus, other sets of seals have been running in alpha testers vehicles for thousands of miles without issue.

Now that we have that covered, let’s talk a bit more about the design of the seal and how it works.

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-

It’s no longer just a washer with one sealing surface – it’s a cup. So it seals in the OEM location AND along the side of the cup. The secret is in the design (which is all thanks to @Tokay444 from MazdaSpeedForums).  The lip at the bottom of the cup is flared just a bit so that it crushes down tight against the cylinder head, and as it crushes down it also crushes outward, pushing against the wall of the port much like an O-ring. If you are having trouble visualizing the flared lip crushing outward then check out the image below. Time to get technical!

FEA-COrkSport-Injector-Seals

Looking at this side view of the seal, you can clearly see that the flared lip is extended further outward than the side of the seal. (Please note that in this FEA, or Finite Element Analysis, the deformation scale factor is 6.5:1, i.e. highly exaggerated). This design is what separates the CorkSport seal from any other seals on the market today. In the FEA the seal is subjected to 3300lbf in the direction of the arrows; 3300lbf is the approximate clamping force of an M8x1.25 torqued to 18ft-lb. The areas in red indicate a displacement of 0.0057 inches, which is just enough to begin yielding (permanently bending) the beryllium copper material. After the 500 miles of use, we had the four seals precision measured using a CMM (Coordinate Measuring Machine). On average, the seals yielded 0.0015 inches confirming our FEA.

Still following?

So what does this mean to you? When you torque down the fuel injector bolt and clamp you are applying approximately 3300lbf to the injector seal. This crushes the seal downward pushing the flared lip outward into the wall for ultimate sealing strength; and we have all the data to prove it! The CorkSport seal works flawlessly, but because of the design they are not reusable like any other crush seal.

So, now that we are done with all the technical stuff let’s take a look at the used seals. First, I would like to remind you what the injector looked like with the OEM crush washer and only 4000 miles.

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Info-Tech-Injector-Fuel

Extremely dirty with an excessive amount of combustion gases blowing by the OEM injector seal. This makes for a very unhappy MZR. Second, in the images you are about to see, the seals have not been cleaned in any way, shape, or form. I pulled these out of the car and immediately took the pictures. Prepare to be WOW’d; I know I was…

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Info-Tech-Injector-Fuel-2

 

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Info-Tech-Injector-Fuel-3

Besides the clean injector body, there is a more subtle detail that needs to be pointed out. If you look at the very edge of the flared lip on the seal you will notice that the black soot does not go all the way to the edge. This further confirms that the seals are working the way Brock (@Tokay444 on MSF) had envisioned them and we can also see this “clean ring” in the cylinder head below.

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Info-Tech-Injector-Fuel-Inside-Intake-Manifold

In the image below you will notice that the seal is dirty on the inside, but that’s okay – that happens by design. The “shelf” that you see midway up on the inside of the seal seals against the injector body instead of in the OEM location further down around the injector nozzle. This change in sealing location allows the flared edge to deflect how it needs.

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Seal-Dirty

If I haven’t convinced you yet why you need injector seals for your Speed3 then you’re hopeless…you should go get a Civic or something else that’s slow…

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Full-Injector

Between our results and the reviews given to us from our alpha testers we have great confidence in the seals and you should too! Keep an eye out for these to be released very soon! Zoom – Zoom! -Barett, CS Engineering