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.

 

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.

Interior LED Light Set for 2016+ Mazda CX-3 and Mazda CX-9

Sometimes it’s the simplest changes to a vehicle that can really make a difference.  A crisp and well-lit interior makes for a surprising improvement. CorkSport is proud to announce that we now have LED kits for 2016+ Mazda CX-3 and 2016+ Mazda CX-9.  

The CorkSport LED Light Kit replaces all interior and some exterior lights that are normally yellow incandescent bulbs.  All CorkSport LEDs are the 7000k color for a pleasant, but bright and clear illumination.

Check out a comparison of the CorkSport LEDs vs the standard incandescent bulb.  

Sure, you can probably find some random lower-quality LEDs online, but only at CorkSport will you get a complete kit with exactly the bulbs you need along with color installation instructions, a CorkSport tin and top notch customer service.  

-BS @ CS

2016+ CX-3 LED KIT         

2016+ CX-9 LED KIT         

An Inside Look at CorkSport R&D

All CorkSport products go through an extensive process to ensure they are the best fitting, looking and performing parts that they can be. As a product development engineer, I see all of these steps on a day-to-day basis, but we don’t often talk about how an idea evolves into a CorkSport part.  Sit back and read on as I give you a glimpse of what goes on during CorkSport R&D.

Concept and Planning

All parts start out as an idea. They come from many sources: employees, forums, car shows.  One of our biggest sources of ideas is YOU! Check out the blog on submitting product ideas for more info on how our customers give us their thoughts.

At the beginning of each quarter, all product ideas are evaluated to determine which are feasible and which are going to be pursued moving forward. After the extensive list is narrowed down, they go into a more in-depth evaluation.

This includes defining the scope of the project, how many man hours it is expected to take, evaluating all expected costs of production, and setting a retail price. Without this evaluation, we would encounter all sorts of roadblocks along the way that would delay getting parts out to you all. If everything is looking good, the project is approved and moves forward.

R&D Begins

At this stage, it’s time to get our hands dirty (literally in some cases). First, we investigate the car the part is for and the scope of the project to understand exactly what the goal of the part is. Doing this allows us to find all design constraints and look for things we may not be expecting. Replacement part diagrams and factory service manuals can be vital here, especially if we do not have a Mazda or Mazdaspeed readily accessible.

By now we usually have a good idea of what features we want the part to have and can move forward with creating an “MVP”. A minimum viable product is just what it sounds like. Not necessarily pretty or optimized yet but good enough to get to see if an idea will work and to check fitment. During MVP creation we have to consider all design constraints, desired features, integration with other CS parts, and even how to manufacture the part. Check out the changes below from an early MVP to the final design for our GEN3 TMM.

If the part can be 3D printed, we print the initial MVP and test fit. Test fits are by far the most unpredictable part of the whole process as sometimes we discover an issue that can change an entire design. Depending on the part, we can have one test fit and be good to go or four and still have work to do. Once we have revised the MVP to a point where it fits well, looks good, and can be manufactured relatively easily, a functional prototype is produced.

Functional Prototypes

This is where the fun really begins; test fitting is a 3D print is one thing, having the part made out of metal is a whole new story. Depending on the part, we sometimes have to skip directly to this stage as it cannot be easily printed in-house. We always have to be careful doing so to limit the number of expensive prototypes we have made. Sometimes this goes well, other times not so much… This swaybar prototype was limiting suspension travel.

A functional prototype also allows for any testing that we may do. Whether it be on the dyno, track, or on the street, all CorkSport parts are used and abused to ensure they hold up to what you can throw at them. Check out an early CS Throttle Body getting tested on a flow bench.

If we are happy with a prototype, this is where you all can get involved again. We often use “Beta Testers” to get another opinion on the part and to see if they come across any issues. From here we sometimes have revisions that need to be made and another prototype produced but ideally, we are ready to move on.

Manufacture & Prep for Release

From here we move to getting the parts made. Sometimes this is a process that only takes a few weeks, other times it takes many months to complete. The manufacturing method, type of part, and order quantity play a big role here. Additionally, some products have a lot of different parts to make up a whole CS product, so each individual part takes time. Sometimes, we even get to see something unexpected, like these Command Wheel Covers before getting anodized black.

While all of this is going on, we are also preparing the product for release. That way, when our manufactured parts show up, we are ready to send them out to all of you. Installation instructions are created, QA checks are set up, laser etch files are set up, product images and video are taken, the web page listing is set up, and so on. Any and all of the content you see on a product is all created in-house. Engineering school definitely did not prepare me for shooting high-quality photos and video!

Check out a “behind the scenes” look at one of our videos:

At this point, we are pretty much ready to bring the new CorkSport Mazda or Mazdaspeed part out to you all. Throughout this process, we are constantly thinking about the experience someone has when they buy the part to ensure it is something that we would be proud to have on our own cars. After all, we build our dream cars using CS parts just like you do!

-Daniel