Mazda’s Dynamic Pressure Turbo – An Introduction

The SkyActiv 2.5T has been around for a few years in the CX-9 however, things started to get interesting when the engine was dropped in the Mazda 6 for 2018. While lacking a manual and not a true Mazdaspeed, it’s a step in the right direction for the enthusiast. With one of the new Mazda 6s in the CorkSport garage, we’ve been getting curious about where all of that 310lb-ft comes from. Well we decided to call up Mazda and purchase a turbo to see how it all works.

There’s a lot to take in on the turbocharger and there are quite a few things that have changed from the K04 that made its home in the Speeds.

For starters, this turbocharger is pretty big. The wheels themselves are not large, with the compressor wheel very close in size to the old K04 & the turbine wheel only slightly larger than the K04. However, with the dual inlet turbine housing, 90° compressor outlet, and lots of attached electronics, the whole package takes up a lot of room in your engine bay.

The turbine housing is not far from the old K04. A large five-bolt inlet flange has two rectangular inlets to work with the dynamic pressure system (more on that later) and even a port where the EGR system sources its exhaust gases. The outlet is much simpler, using a five-bolt flange to mount to the downpipe, yet does house a surprisingly large wastegate port.

From a performance standpoint, the large wastegate should help eliminate boost creep but the turbine housing will likely need a larger scroll to get some more serious power out of the engine.

The compressor side is packed full of features. As usual, the wastegate actuator bolts to the compressor housing, however, Mazda has switched to an electric actuator. Interestingly, the bypass valve is also electric and is even mounted to the face of the compressor housing.

Some fancy casting design leaves a pathway between the high and low-pressure sides of the compressor and lets the BPV decide when the passage is open or closed. These two electric actuators will mean easy and consistent boost control. The final plastic component on the housing we believe is a boost assisted vacuum source for the vehicle. Finally, the inlet is a typical clamp connection while the outlet uses a 90° turn and two-bolt flange for better accessibility around the wastegate actuator.

With the housings removed, the CHRA of the dynamic pressure turbo is very simple & standard. Oil feed in the top, two-bolt oil drain in the bottom, and standard crossflow engine coolant ports. The compressor wheel is a cast 6×6 unit and turbine wheel is a basic 11 blade unit.

We are looking forward to waking up the Sky-T in the coming months and making the 2018+ MZ6 into something a little closer to a Speed. Stayed tuned, there’s much more fun to be had from the 2.5T!

-Daniel

CorkSport Steering Wheel for ND Miatas

We love the look and feel of the CorkSport Mazdaspeed steering wheels and thought we would throw some love to the Miata guys. Designed to inspire confidence during aggressive driving while improving day to day comfort, this steering wheel is a complete package and will complement your other CorkSport Performance Upgrades.  

 

The CorkSport Steering wheel is a direct OE replacement as it retains all trim, buttons, airbag, and even paddle shifters for automatic models. It’s also a perfect fit for all ND Miata models (yes even those of you with a RF). Check out the image below, it shows exactly what you will get in the box (right) next to an assembled performance steering wheel (left). Once you remove your OE wheel you just need to transfer all of the trim and accessories and you’re ready to install.

 

 

In designing the wheel we knew we wanted performance without sacrificing comfort. Let’s face it, the steering wheel is the one thing you are (hopefully) always touching while driving. We knew right away we wanted a thicker wheel as the stock one is awkwardly thin. We increased thickness without increasing the overall diameter of the wheel.

 

The flat bottom of the wheel makes it easier to get in and out of the car, especially for those of us who barely fit in Miatas anyways. To further enhance the aggressive style we added a center stripe to the top of the wheel. Finally we carried over the deep thumb grooves from the CorkSport Mazdaspeed 3 steering wheels to really lock your hands in place during spirited driving.

 

All of the features are wrapped up in plush black leather, with perforated leather on the high use areas to keep your hands cool. If that wasn’t enough we’ve also added an option for alcantara inserts. Why?  Because Racecar!

 

If you’re looking for an easy mod that will upgrade the feel, comfort, and style of your ND Mx5 let the CorkSport Steering Wheel find a home in your interior.

All About That CatBack Exhaust

Mazda Catback Exhaust Installed

Ever wondered the key factors of making a decision about your aftermarket exhaust? Why Cat-back? 

Is it the diameter of the exhaust that says performance? Or is it the type of metal used? What about fitment to your current setup? None of these questions by themselves answer what you need by themselves, but all of them together help when making the decision on how to get more power out of your Mazda.

At CorkSport, we have made it our #1 priority to make our customers dreams a reality. Whether you drive a Mazdaspeed or a regular Mazda, we’ve made sure to engineer a great fitting exhaust that maximizes engine performance.

Check out the Cat-Back Exhausts by Car Model Below:

Take the Mazdaspeed 3 for example: When you purchase a CorkSport Catback Exhaust, you’re getting T304 stainless steel piping that has been polished to a mirror-like finish.

You’re also getting true 80mm piping, which is slightly bigger than three inches, making our exhaust one of the biggest bolt on catback systems.

Fitment is also a big concern to us. We make sure our exhaust systems are mandrel bent and TIG welded to make a perfect bolt-on fitment.

Mazda 6 Power Series Exhaust

Now that you know our exhaust is 80mm piping, polished to perfection, and made to be a direct fitment, you can bet this exhaust will increase performance and sound. By installing our cat-back exhaust, you’re removing the secondary unmonitored catalyst making the exhaust flow much faster out of the motor. By increasing the velocity of exhaust gases out of the motor, you increase power and make your turbo spool up a little bit faster.

Among the power gains you’ll see from installing the CorkSport Catback Exhaust, you’ll also have a car with a deep growl to it. Our exhaust has one of the best sounding tones on the market. With a quality made exhaust, comes quality sound.

When find yourself ready for a cat-back exhaust, be sure to check out CorkSport to ensure you get the highest quality for your ride.

 

CorkSport Cat Back Exhaust for CX-9

Time to bring some CS love to those who need some more space than what a hot hatch can offer. Introducing the CorkSport Power Series Cat-Back Exhaust for 2016+ Mazda CX-9 AWD.

The CX-9 has great potential with its turbocharged 2.5L engine but it is bottlenecked by the small stock exhaust. The CorkSport catback ups the exhaust diameter to 80mm (from the OE 60mm) and utilizes high flow pass-through resonators to really help that turbo breathe better.

To go with the better performance, the CorkSport cat-back also looks great. Made from CNC bent, fully polished, T-304 stainless steel, it’s definitely an attention grabber that will stay looking great for years to come. The dual exhaust tips were upgraded to 100mm outer diameter and extended to really fill out the bumper cutouts. Don’t worry though; the tips are noticeable without being obnoxious and detracting from the clean look of Mazda’s Kodo design philosophy.

Last but certainly not least: the sound. The upgraded piping diameter and less restrictive resonators combine to create a sound that is certainly louder and more pleasant than stock without being unbearable for the daily commute. You hear the exhaust when you want to but it quiets down while cruising and does not drone. As a final bonus, you get a little taste of turbo noise as it spools up. Check out the video down below to hear a comparison between the CS CX9 cat-back and the OE exhaust for yourself.

All of these benefits come with the same CorkSport quality and customer service that you all have grown accustomed to. This means OE style fitment that retains all existing exhaust hangers and oxygen sensors since no one likes a check engine light.

Whether you have moved on from a Mazdaspeed but miss the sound or just want to spice up your grocery getter with a little extra noise, the CorkSport Mazda CX-9 cat back is an upgrade that hits all the right notes. Check out the product listing for full details.

 

Want more for your CX-9? There may be a few more things coming down the pipeline, but submitting a product idea helps us to know what you’re looking for!

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