2018 Mazda 6 Performance Parts – Cold Side Boost Tube

You have probably heard us mention the new Turbocharger Mazda 6 in the recent weeks and months and have probably been wondering; “what’s going on?”  Well, today we’d like to share a little bit about what’s been going on at CorkSport HQ with our very own 2018 Mazda 6.

Right off the bat, I can say we have a handful of exciting performance products in the works and will be sharing info on them as we make progress.  Today we want to talk about the intercooler piping, specifically the cold side piping and the parts of the system. This is the piping that connects the outlet of the intercooler and the throttle body.  It is commonly referenced as the “cold side piping” because the charge (boosted) air has passed through the intercooler and is therefore cooler.

The OE cold side piping consists of three main components.  Starting on the right side of the image; we have the hard piping that connects to the intercooler and a soft rubber hose.  Next is the soft rubber hose itself, which we will talk more about later. Lastly is the throttle body connection, which is the oddest part of this system.  You can see why in the next image.

The above-mentioned intercooler hard pipe and the rubber hose are pretty common parts on modern turbocharged vehicles, but the throttle body connection is unusual from our experience.  The throttle body connection appears to be designed for a quick connection (and not so quick disconnection) during the vehicle assembly process. Unfortunately, this leaves a very odd connection flange on the throttle body itself.  Lastly are the fins inside the connection part; other than straightening the airflow entering the throttle body we don’t see many purposes these. We will be testing the effects and need for these in the near future.

Now let’s get to what we really wanted to talk about; BIG Silicone Performance Parts.

Mazda designed the Turbocharged 2.5L SkyActiv-G to function at a specified boost pressure and no more.  However, we fully intend to change this set boost pressure for increased smiles per gallon. With increased boost pressure comes more force and strain on the OE rubber hose.  Eventually, the OE rubber hose becomes too flimsy for the increased boost pressure and may expand or fail completely via a rupture.

So how do we develop a performance part to replace a rubber hose?  Well, there is one obvious improvement and another not-so-obvious change that can be made.  First, we use silicone as the prominent material for its excellent heat resistance and durability.  Next, the silicone is reinforced with five layers of fabric braiding to withstand the increased boost pressures.  Compare this to the OE single layer of reinforcement and you can see why this would make a big difference.

Now for the less obvious performance improvement; the CorkSport 3D Printed prototype is larger in diameter than the OE rubber hose.  Leaning on our experience with past intercooler piping development, we have found that increasing the charge air volume directly in front of the throttle body increases throttle response and helps spool the turbo faster, reducing turbo lag.  

Currently, we are still in the development phase but will be testing soon.  Stay tuned for future updates on the CorkSport Performance Boost Tube and other exciting products for your 2018 Mazda 6.  

-Barett @ CS

2016+ CX-3 Axle Back Exhaust

Breathe Some More Life into Your CX-3

Bought a new CX-3 and wish it was a little more exciting? CorkSport can help with our lowering springs, short ram intake, and now we are proud to introduce the CorkSport Axle Back Exhaust for 2016+ Mazda CX-3 AWD.

The CorkSport axle back really gives the little bit extra that the CX-3 needs to be a fun & practical little car. By increasing the piping diameter to 60.5mm and using dual high flowing resonators, the CS CX-3 axle back provides much better sound than OE without being “buzzy” or annoying like so many exhaust option on the market. It’s louder than OE but not drastically so, plus, it avoids any drone while cruising down the highway. Check out the video below to hear how the CorkSport axleback sounds.

To go with the sound the CorkSport CX3 axle back looks great. Made from fully polished T-304 stainless steel, it will add some style to the rear of your CX-3 right away and stay looking good for years to come. The tips have been enlarged to 90mm, slant cut, and lengthened slightly to really fill out the bumper cutouts. For a final detail, a stainless CorkSport nameplate is attached to each tip and just barely peeks out from under the bumper.

As usual, you get the same OE fitment and reliability that you can always expect from us at CorkSport. As a result, this really is a no drawback product that adds a little bit more excitement to the CX-3. If you want to add some extra sound and style to your CX3 look no further than the CorkSport Axle Back Exhaust.

 

Brett’s Build Part 3

Well guys, I am back with a part 3. I apologize in advance for the delayed release of the 3rd chapter, but the Mazda was out of commission for a bit getting some stuff reworked! That being said, we can now pick up where we left off in part 2!


As I started to settle into my new stake at CorkSport, I started adding on lots of new goodies. At the beginning of the new year of 2017, I got to throw on our prototype Stage II RMM and get rid of my old one for some testing and feedback. Not only did the vibes decrease substantially, it also held the powertrain better and was helping my wheel hop significantly. So while I was at it, I threw on a Lower Tie Bar to help even further, knowing I had plans in the very near future to make over 400 Whp.


It was now Feb. of 2017 and I knew I was wanting to reach my new power goal by Summer. So, I talked to my tuner, Erik with Drama Tune, and scheduled to fly him up here in March to dyno tune the car. I had every single piece needed to complete the 400+ Whp puzzle.

The last missing piece was fuel. At this point in time, I had two options, Port Injection or Methanol Injection. Given, that I only needed a little more fueling head room freed up I went with methanol for ease, and price. For those that are curious, I purchased the Snow Performance Stage 3 Kit.  

I started installing the kit at the beginning of March 2017. Since I was going to be putting bungs into the FMIC piping, I got the kit powder coated as well.  I installed one small nozzle right off the cold-pipe of the intercooler, and another large nozzle right before the throttle body. I left a couple inches to help the alcohol atomize. The total amount I was spraying between the two nozzles was approximately 1000 CC’s of 100% Meth as we were using it for Fuel.  

So, with the car ready my Tuner flew up and we got my car on the Dyno! Keep in mind my car is a stock bottom end, so I knew I was going to be playing with fire a bit. The general rule of thumb here: If you are on a stock bottom end and want to push the car in this fashion, always have a backup plan ready in case the engine gives out.

By the end of the session, I had 3 maps from Erik:

Pump Gas: 340 Whp

E85 Blend (3 Gallons): 390 Whp

Methanol Injection: 430 Whp. (e85 still in the tank for added knock resistance and cooling)

The torque was kept down as much as possible at 380 Ft-lbs @ 4700 RPM. So, the stock rods definitely were not in danger. Ultimately if the block were to give out in this situation, it would more than likely be the piston rings. The stock Piston Rings do not like high heat or harsh temp changes. So, the best thing you can do pushing 400+ hp on the stock bottom end is to allow time between pulls for everything to re-stabilize. This will ultimately increase the time you have before it ‘Splodes. Because, if we are being honest with ourselves, at that power level, its always a matter of when, not if with the stock block.

 



So, this is how my MS3 has been for the last year or so power wise. Built block will be in the future soon. But on this next part, I’ll dive into some cosmetics details that I’m sure a lot of people wants to know.

*Hint* “Hey Bro what flares are those”

-Brett@CS



Stopping power for the Mazdaspeed6

With our goals to make more power, we often forget about the opposite requirement so speed…stopping. The CorkSport Big Brake Caliper Kit is a great place to start, however, if you wish you could stop even faster say hello to the CorkSport 13inch Big Brake Kit. Designed for serious stopping power, it includes 13” directional rotors, powder-coated 4-piston calipers, upgraded pads, and everything you need to install it on your Mazdaspeed 6.

Read on for a breakdown of all the components:

2-Piece Rotors

Lots of thought has put into the design of the performance rotors found in the CorkSport 13inch BBK. The upgrade to 13inch diameter rotors provides greater braking torque for an equivalent braking force (like how a longer wrench makes it easier to loosen a tight bolt). The increased diameter combined with a thicker 28mm (vs 25mm for OE) rotor ring provides better cooling as there is a larger mass to reject heat into.

In addition, slots were added to the friction surface to help sweep away any debris, brake dust, or gases that can otherwise affect your braking characteristics. Drilled rotors were not used as holes decrease your total friction area and increase the chance that the rotor will crack. Utilizing a two-piece design, we were able to decrease the overall weight of the rotor via center section produced from billet aluminum; while also helping dissipate heat from the rest of the rotor better. Semi-Floating mounting between the inner and outer sections allows for quieter rotor vs having a full-floating center section.

Lastly, the rotors feature directional internal vanes that promote more efficient airflow through the rotor which further increases the rotors ability to dissipate heat. By using curved vanes instead of the typical straight vanes, the rotor becomes directional and has to be used on a specific side of the vehicle; however, it also provides more efficient cooling. When the rotor turns, the curved vanes draw air through the center of the rotor and out through the edge, providing greater airflow than a straight vane and thus better cooling. There is another bonus to heat dissipation as the curved vanes have a larger surface area that will come in contact with air than an equivalent number of straight vanes.

Forged Calipers

Four-piston performance calipers manufactured from forged aluminum are included with the kit in a choice of powder-coated blue, red, or black.

Although each piston is individually smaller in diameter than the single OE caliper piston, the total surface area is increased so the braking force at a specific brake pressure is increased. Larger piston surface area means larger brake pads can be used as well. You also get more even braking force on each side of the rotor due to the opposed piston design. This encourages even pad wear, even rotor wear, and consistent braking characteristics. The piston diameter and material were chosen for optimum braking endurance and reliability. They are staggered in size, with the pistons on the leading edge being slightly smaller than the trailing edge pistons. This is another protection for even pad wear. Each piston is made completely out of stainless steel for its low conductive heat transfer. What this means is that the pistons themselves will transfer less heat to the brake fluid than an aluminum or steel piston, decreasing the chances of overheated brake fluid.

Performance Pads

Street performance brake pads are included with the kit. The street sports pads bridge the gap between street and trackpads. They are a more aggressive compound than the pads included with the CorkSport Big Brake Caliper Kit but are not a full track pad. They will produce less dust and noise than a track pad but still need to be warmed up for optimum performance. Should you need new pads or want to change to a different pad, you have a bunch of options from G-Lock, Carbotech, EBC, Hawk, and various other manufacturers.

Lines, Brackets, and Hardware

The remainder of the CorkSport 13inch BBK is composed of exactly what you need to properly and safely install the kit on your MS6. Coated stainless steel brake lines are included to remove any risk of a soft brake pedal and ensure the calipers are operating optimally. High strength billet steel brackets properly position the four-piston calipers on the new rotors using the OE bracket locations. All components are locked down using Grade 12.9 hardware with a corrosion resistant coating for lasting durability.

The CorkSport Mazdaspeed 6 and Mazda6 13” Big Brake Kit has everything you need to keep you safe at increased horsepower levels. If you’re looking for more than the stock brakes have to offer, let the CorkSport BBK be a part of your build.

CorkSport and Mazda Events

I absolutely love it when the fantastic humans at Corksport approach me to blog it up for them.  So let’s dive right in, no time to waste.

August is kind of a sad month if you look at a calendar.  No real holidays to speak of, it’s hot and miserable across the entire United States, and with the exception of Vigil of Assumption Day(whatever that is), August is kind of boring.  But, look no further than the CorkSport’s Dyno Day, Show & Shine and Drag Racing on August 25th!!! It’s almost like Christmas in August. Free stuff, raffles, food and drink but most importantly, great people.  Be sure to let them know if you are coming on their EVENT PAGE!

Oh, you forgot who I am.  Well, I put on one of the craziest meets for us Mazda junkies.  Mazda Takeover, yeah, I’m that guy that annoys you on the Facebook groups reminding you to come and have a weekend of a lifetime.  You might be wondering what that has to do with a Corksport Dyno day? I will gladly tell you.

Corksport has gotten behind Mazdaspeed Idaho’s little shindig in a big way.   You see, the good folks over at CS year after year make the trek, a pilgrimage if you will to Idaho for Takeover weekend.  It’s only right that we return the favor! As soon as CorkSport announced their dyno day event, posts from Mazdaspeed Idaho members flooded our local page with questions, ideas, plans and straight up commitment to making the trip to CS in August.

I might be a little biased about the Mazdaspeed Idaho group being the best group of people ever, and they are. The cars in Mazdaspeed Idaho may not be showpiece material, nor are they the fastest on the planet, but us members love our Mazda’s as if they were show cars or all out HP cars.  

Hell, one member sold his Gen 1 speed and within a year picked up a Gen 2 just because he loved the community more than the other community options given his other cars, so that’s saying something about not only the Mazda brand, his local Mazda community, but it says a lot about Corksport as well.  Having owned his new Mazdaspeed 3 less than a week, he was the first to commit to wanting to go with the group that forms to the  CorkSport dyno day! He is beyond excited to meet the people and see the building where his car part dreams come to fruition.

As of right now, I’m guessing Idaho will roll into Vancouver with 10-20 Mazda’s, which is a huge improvement over the 4 we took last year.  I’m really looking forward to this event, mostly because it gives the Western Washington Mazdaspeed and Nator OR communities another group to bond with.  Which is what Mazda should be about, forming and building a strong, unbreakable community that forges lifelong friendships through one shared passion.  I really hope some California members make the trip as well. It’s always refreshing to see other Mazda’s, other ideas, and other builds.

I didn’t ask my boss, I told him I won’t be available because I have race car stuff to do with my race car family.  And you all should tell your boss the exact same thing, and show up for one hell of a weekend out at Corksport.

See you @ CorkSport August 25th!

 

Keith Eggert