Collaborating with CorkSport – R&D for the Community

My name is William Dawson; for those who do not know me, I am owner/tuner at Purple Drank Tuning. In this Guest blog, I want to bring up some of the research & development I was able to contribute to with CorkSport (behind the scenes) to help bring some new performance parts to the Mazda community.

One day, many months ago, I was approached by Barett@CS to help with the tuning and development of some mystery parts CorkSport had in the works. Being who I am, I couldn’t turn down the chance to work on some new projects that could help continue to push the Mazda platform we love.  

With the pleasantries out of the way, we got down to the plan and the data.  Barett had a list of goals and how he wanted to move through the parts in testing.  The amount of data that was communicated through the first live tuning session was great. On the CorkSport in-house dyno we took their shop car to an impressive 420whp (e48 + 6 port setup) with stock manifolds, stock throttle body, and stock camshafts.

This laid the groundwork and set the stage for their product release of the CS Camshafts which gained 22whp across the curve. Along with the power increase, the camshaft upgrade also netted surprising results with turbo response.  The turbo spooled 100rpms quicker than the factory camshaft allowed. THESE ARE DROP IN RESULTS, ZERO ADJUSTMENTS! 

Mazdaspeed camshaft

Efficiency hit us with another surprise when we decided to put the CS Intake Manifold (set to re-release in early 2019) on the car and help the engine balance all of the air we have begun shoving into our test vehicle. Once again CorkSports engineering pays off with another 9whp increase and 100 rpm quicker spool up. The car lost 2-3 psi of boost which we were happy to put back in the car allowing for us to do an apples-to-apples comparison but the numbers elude me so I cannot speak to what we ended up with on that day. 

 

Mazdaspeed 3 intake manifold

 

At this point we did not know how much more we could get as the CorkSport Mazdaspeed Drop-In Turbo that was installed on the test car was producing an impressive 450whp, this did not stop us as we needed to test one more item. In comes the CS 72mm Throttle Body, this upgrade was constantly overlooked by the Mazdaspeed3 and Mazdaspeed6 community because of other attempts to get an upgraded throttle body created complications with drive by wire tables and throttle response.

Personally having a 75mm TB and not being able to enjoy the on/off throttle response and laggy part throttle was a very frustrating experience; one that even made me skeptical.  Then getting to test CorkSports product was MIND BLOWING! The test car again spooled around 100rpms sooner and throttle response was phenomenal; all with just removing 4 bolts and swapping a Throttle Body this is insanity. This team did it again, my disbelief overshadowed by pure joy that they developed a working unit and it far surpassed the factory unit in throttle response and driveability. 

 

Mazdaspeed3 72mm throttle body

 

I have known the CorkSport family for years and it does not matter what department I am working with they are always on point and pleasant to deal with regardless of the situation. Between PD and CorkSport I could not be happier to invest countless hours of hard work and R&D to allow this winning family to provide further developments and support to the Mazdaspeed 3 and Mazdaspeed 6 platforms. 

 

– Will Dawson (PD Tuning)

 

Special thanks to Will for committing his time and expertise to help CorkSport continue to grow and support the Mazdaspeed community.    – Barett @ CorkSport

Creating CorkSport Parts with 3D Scanning

While creating a new CorkSport part, we sometimes run into issues where calipers, bore gauges, and angle finders are simply not enough to get the measurements we need.  We’ve discussed how we use 3D printing in a previous blog, but today I thought I’d go over the opposite: 3D scanning.

Where 3D printing takes a CAD design from computer to physical part, 3D scanning takes a physical part and converts it into a computerized model. This is especially useful for things like intercooler piping, intake design, and even creating exterior body parts. What these components all have in common is that they are a complex, difficult to measure, shape where fitment is critical. Check out the 3D scan below from the development of our GEN2 Mazdaspeed 3 front lip. While not a perfect replica, this 3D scan information was vital for designing the CS front lip to ensure great fitment and stylish look.

At CorkSport, we do have a small 3D measuring arm that can take measurements of 3D objects and input them directly into a CAD program. The arm does this by first having a “home” position established that the arm can measure from. Then as the arm is moved around, it knows how far the tip of the arm is from the home position in x, y, and z coordinates. This is a very basic form of 3D measurement as the arm must actually touch the surfaces of the part. Mostly simple information like mounting surface locations, angles, and hole sizes can result from this arm. While not a full 3D scan, it is especially useful for things like the GEN3 Transmission Motor Mount that have mounting planes at different angles.

For intercooler piping with completely round surfaces and bends, CorkSport’s 3D measuring arm has its limitations. We typically get a full 3D scan performed on the OEM piping to give us solid locations and a great visual reference to design from. The 3D scanning arm bounces a laser off the part to determine its shape and size. Then, software that accompanies the 3D scanner stitches all the information together into a full 3D CAD model. The scans achieve great accuracy; check out the embossed writing and even texture on this OEM intercooler piping for the SkyActiv 2.5T.

From this point, we design the new CorkSport parts. In terms of intercooler piping, we analyze where the larger piping will fit to get the performance gains we want. In some cases, we can also simplify the pipe routing to get smoother airflow than the OEM piping. Having a full OEM piping scan makes this much easier as we can easily double check our measurements with the OEM parts on the car. As a result, our first 3D print can often be the final version before having metal parts made. An early design for an upgraded Mazda 6 SkyActiv 2.5T hot pipe is shown below (blue) with the OEM part scan (gray). The routing was carefully chosen to achieve our desired piping size within the constraints of the OEM engine bay.

 

3D scanning has a huge range of uses and we are just beginning to explore the full capabilities. Be sure to share your ideas on how we should use this technology and what new CS parts we should make with 3D scanning’s help!

-Daniel

CorkSport 7th Gear

Become of member of our new, exclusive program 7th Gear and get gifts, early access to new products, and more!

You’ve likely seen a quick glimpse of our 7th gear program previously, but there is NO WAY you have made it this far knowing all of the benefits and still not pulled the trigger.

There is just no way… and if so…You are MISSING OUT!

We’ve loved how this program has grown over the last year, with members giving product ideas, insight into their builds, and passing the EXCLUSIVE info on the gains we’re experiencing on our prototypes; it has truly become a community of enthusiasts. With pushing one another for higher power and better builds as a center, great parts, and direct insights provide for instant feedback and inputs on projects.

Become of member of our new, exclusive program 7th Gear and get gifts, early access to new products, and more!

If you haven’t heard, or looked fully into this program, here is a brief overview and some insight directly from our members!

As a 7th Gear Member, you’ll receive …

An exclusive gift package worth $99 when you sign up.

    • You can only get these apparel items by becoming a 7th Gear member! – worth the cost of the membership by itself!!

CorkSport's exclusive new membership program, 7th Gear, is all about building a family of dedicated Mazda enthusiasts.

Access to our exclusive 7th Gear Facebook group.

    • We’ll provide insider information on our products, lifestyle, and happenings!

    • You’ll interface with other elite members of the Mazda Community and receive CorkSport answers faster than anywhere else on the web.

    • You’ll have first access to new product releases via the 7th Gear Inner Circle thanks to your membership

 

If you’re buying anything with a significant shipping cost, it would be patently stupid to not get the 7th gear membership. The hat is top quality flex-fit and the shirt is nice too, big vinyls if you’re in to that. Exclusive access to sales, skipping the line on new parts, and you get behind the scene access for product development. Combined with CS points it’s a much better offer than competitor’s “free shipping”. – Jason Gambill

Free Shipping to the lower 48 States. (Hawaii, Alaska, and International orders get reduced rate shipping.)

    • You heard us right! Free shipping to lower 48 and reduced cost shipping for our members elsewhere!

 

“Do you love buying Corksport parts for your Mazda? Then why wouldn’t you want to join 7th Gear? Early information on upcoming parts so you and your wallet can plan ahead. Corksport is one of the few companies still developing new and exciting products for the Mazda/Mazdaspeed platforms. Why not join them and get an even deeper inside scoop!  Even though I’m in Canada and I don’t get free shipping, the discount I receive does help! The cost of 7th Gear could be covered from just a couple orders.
And even the occasional sale exclusive to 7th Gear is great.” – Michael Cheek

Automatic Annual Renewal that includes an awesome anniversary gift worth, at least, the cost of membership!

    • Once again, no one has access to this exclusive gift item unless they’re a 7th Gear member!

As a 7th Gear member, rest assured that we’re here to ignite your Mazda dreams into reality. With first access to parts, exclusive gear, exclusive 7th Gear promotions, and direct links to our CorkSport team, the free shipping is just a perk. Head to CorkSport.com for more information on 7th Gear today.

Why do you need an OCC ??

For those that don’t know exactly what an OCC is for, here is a quick rundown.

  1. During normal operation of an internal combustion engine, there’s a compressed air and fuel mixture inside the combustion chamber that is ignited and as a result, forces the piston down. A small amount of that ignited mixture leaks past the piston rings and ends up in the crankcase. This leakage is often referred to as “blow-by” (leakage past the piston rings), and is the reason every car has a PCV System in place (Positive crankcase ventilation)

  2. Some of the oil, mist and other products settle along the engine intake and over time form a “gunk.” With newer cars being direct injected nowadays, this becomes an even larger problem when fuel is not passing over the intake valves and keeping them clean.  The OCC collects the PCV vapors and utilizes a baffle to trap the oil, fuel, and water particulates that are suspended in the air.

  3. These liquids will need to be drained periodically (we say with each oil change) of all the ‘junk’. NOTE: Monitoring how fast the can fills up, mirrors as a method of gauging engine heath. More blow by = Quicker Filling OCC.

 

Carl Jacobsen recently reviewed our Mazda3 OCC in an interview, and we’re releasing it here so you can hear it from a satisfied customer, and not just our opinion.

From the start, we have wanted to give our customers the highest quality experience when purchasing the OCC for their Mazda3. The importance of knowing and seeing you have every piece you need to get started is the key to a successful installation.

 

            “ The unboxing is the best part. You know everything is there, even the step by step instructions. (I tried not to use them, but I ended up doing so because they’re spot on all the way down to the bolt sizes).”

All of our installation instructions come with step by step tips and tricks to make things easy along the way. However, if you ever hit a hiccup, just know we’re only a call away!!

 

            “ Installation was a breeze, instructions were spot on, some parts – like the mount are hard to install without help, but nothing you couldn’t do on your own…  ”

As far as the CorkSport Mazda3 Oil Catch Can goes, knowing that all the crankcase vapors are getting filtered out, allows for you to have that peace of mind that your engine is cleaner. Without filling up the space in your engine bay!

 

            “The OCC is hidden, it doesn’t take up space in the engine bay. You’d never know it was there unless you follow the lines. Also, the ease of access to drain it was a highlight! There was more than enough tubing to route the drain plug to the easiest spot, so you can drain it when changing your oil.”

  • Brett White

Join the Mazda Family

Oh man, where to start.

               Day one, was a 6-hour drive from Utah to Boise Idaho. I was supposed to head out with a couple of other Utah guys, but they were not able to make it. I was on my own for 6 and the only thing going through my head was, “I’m on my own, driving to a town I know no one in, I have zero friends and that I’ll probably be the only Mazda 3 there”. I made it my goal to make friends wherever it is I go or else this was going to be a alone and this trip would have been a waste. As I get into town I settled into my Airbnb and decided to hit the town. I only saw one speed that night but I was anxious for the next day to go to the events start.

                

Day two, I went to this pancake house to grab some grub and I was shaking out of excitement. I head over to Keith’s house and see four speeds outside. I immediately knew I was in the right place. I walk up to Keith and welcomes me with open arms and announces I am the only Utah guy to show up this year. I start talking to everyone and get to meet everyone who shows up and I’m having a blast every one welcoming me to Idaho and the first takeover for me.

Keith announces we will be going to horseshoe bend. A canyon drive day one, one I will never forget. It was a beautiful sight the entire time. Brett hanging out of Corey’s  MX-5 MSM taking beautiful shots of everyone’s cars and even a drone in the sky.

Later that day we head off to start our first competition of the weekend, go-karting. Name of the game fastest lap time wins a prize. I can’t remember who it was that won. Then that night was BBQ night and drinks all around. That’s when I got to meet everyone else who had shown up, share a couple of beers and enjoy the CorkSport koozies that were handed out.

 

Day three, I woke up in my car…well because of the night before.

Saturday was a slow and relaxed day of just hanging out in the garage hiding from the rain. While we hanging out in the garage some of the Oregon guys decided to adopt me and I can join them since I was the only Utahan. I also got to talk to Dale and pick his brain about tuning and learned a bunch about speed that I had no knowledge of as well.  Later that night we head off to the raceway and I’m excited to see everyone run and see lap times everyone was laying down. There were a bunch of cool cars and Barett laying down some fast times on street tires.

Day four, the last day.

Everyone meets up to say their goodbyes, have a beer or two, share some last tales. The few people that have left a great memory for me where Keith, Jordan, Anthony, Aaron, Dale, Brett, Corey, and how could I ever forget Brian. As I head back to Utah with everyone on my mind and how my entire weekend went I wanted to turn around and just stay. I had made new Mazda Friends and Family.

Those four days were ones I could never forget.  The feeling of being accepted into a group of people I didn’t know and didn’t necessarily fit in with was one that cannot be explained. It can only be experienced. When I came back to Utah, I couldn’t stop thinking about my vacation in Idaho. How it ended so soon. How it felt like I started a new life for just 4 days. I want next year to come sooner so that I may meet the friends and family I now have in Idaho, Washington, and in Oregon.  Thank all of you again for the wonderful experience.

Oh yeah, by the way, I am making the drive to the CorkSport Dyno Day and Show & Shine on August 25th – Excited to see my new/old friends!