Product Testing Has Never Been So Fun!

I have finally got some time to polish the washer behind the steering wheel on the 2010 Mazdaspeed 3 and I can without a doubt say it is an unbelievably fun car. I come from a world of cars that have an immense amount of what I like to call ‘Soul.’ Meaning they’re rickety and loud and generally belch mass quantities of fuel out the tailpipe on tipping into the throttle after 7500rpm decel because the 45mm Weber DCOE’s are washing the cylinder walls down like a firehose. So for me to drive a refined car is usually an exercise in complaining about how quiet it is or that it doesn’t have enough of this so called ‘Soul.’ Meaning I feel out of place because I’m actually in a nice car that behaves like it should and also accelerates and handles like a monster. It’s my exercise in self justification that my 70’s and 80’s cars have something that replaces the refinement that I am so dearly missing.

During the product validation phase for our Power Series Intake System we found that the 2010 Speed3 has a very low tolerance for improved intake designs – the window for fuel trim on the 2010 seems to be far narrower than it was with the 2007-2009. And the car runs pig-rich at wide open throttle from the factory, and from what we can tell Mazda wants to keep it that way. Which is ridiculous – maximum best torque isn’t made at 10:1 AFR. We have managed to design a system that pushes the envelope for power and also resides at the upper end of the safe zone as it relates to ECU Long Term Fuel Trims (LTFTs). This required us to spend a lot of time behind the wheel with an OBD2 datalogger to gather data off the 2nd Gen. ECU. We’d then head back to the lab to crunch some numbers and improve our understanding of what the ECU wants to see, what factors effect that and how to manipulate them for safe running and excellent power while simultaneously avoiding the dreaded CEL/MIL light. And no, the first step of the install instructions aren’t ‘Remove Gauge Cluster and cut traces on Tachometer circuit board that lead to check engine LED.’

But wait, this technical background story is nothing compared to the best part – all those hours behind the wheel!! After countless hours of punching up and down the freeway at various levels of cruise, I switched gears and took the 2010 out on one of my favorite loops… Until this point, I hadn’t had a good opportunity to really see what the car was capable of, as most of my time in it was on commutes and around town driving.

For those of you who aren’t familiar with where we’re located, CorkSport is in Vancouver, Washington – right across the Columbia River from Portland, Oregon. Vancouver is in the shadow of Mt. St. Helens, the cascade range volcano that blew 2000′ off its top in 1980. I live about halfway between Mt. St. Helens and Vancouver and the North Clark County area has an amazing array of roads snaking over the landscape. Banked 180 degree curves abound and just when you’re ready to pull over and lean your head out to paint the tarmac with your lunch, the road opens up to 1-2 mile straights that give your inner ear the slightest respite prior to wrapping right back into beautiful Nurburgring-esque sweepers among gorgeous green foliage and narrow cliff-lined lakes.



The Speed3 performed phenomenally. There were plenty of areas for improvement, what with it having stock suspension, no strut braces, factory tires, etc. For the most part, however, it was a blast to drive. The factory brakes are surprisingly capable and the transmission gearing is perfectly matched for putting lots of power down through the curves and even more as the straights open up. The engine management provides a very crisp deceleration with its overrun (deceleration) fuel cut algorithm. There were a number of times when I had to remind myself that I was simply going waay too fast and back off in areas where sight distance was limited, but the car is so smooth to accelerate through 2nd, 3rd and 4th that it’s hard to realize you’re doing 90-100mph.

Coming from a predominantly rear wheel and all wheel drive background, the Speed takes some getting used to when hammering it around corners laying down 300lb-ft of torque. In sharp turns under acceleration, the massive torque-steer requires some elbow grease to reorient the treads to follow the road, but the benefit gained on big sweepers is well worth the tradeoff provided in the FWD drivetrain configuration. This is a wonderful car and if you can get past the torque steer and not be bothered by it (which takes very little time from what I’ve found), the benefits had from the power that causes it far outweigh the initial surprise of how heavy handed the car can be under certain conditions. But for me, the torquesteer is an excellent addition – I think I have slowly identified that what I see to be the feeling of ‘Soul’ in a car is really just elements of a visceral experience – and the torquesteer is the only unrefined and live thing about the car that reminds you that you’re not driving your girlfriend’s Jetta. As automotive enthusiasts we long for these elements in our cars which is why we love to modify them – a throaty exhaust system and an intake / turbo inlet that allow you to hear the turbo spool up both go a long way to bringing your Mazda’s Soul out of its cage and to the surface.

Jason

2010 MazdaSpeed3 First Dyno Results

MazdaSpeed3 Dyno


Just got got the 2010 Mazdaspeed3 off the dyno after doing some installs and have some results to share.

The Dyno run went great for the 2010 MS3. It’s bone stock with three mods – CorkSport Power Series Racepipe (80mm with factory 65mm outlet) and CS Power Series Intake w/ Turbo Inlet and a set of CorkSport Motor Mount Inserts. Each of these products will be released shortly for the 2010 MS3 including some revised design considerations for the new 2010.

The stock baseline numbers for the 2010 were 231hp 269tq (73.8F/45%Humidity). With the two mods, it hammered down 272hp and 301tq (78.7F/43%Humidity).

41hp gain, 32ft lb of torque. Boost went from factory 16.4psi to 18.6. $388! Can’t wait to see what it picks up with the downpipe.

If you have a Speed3 without any exhaust modifications or haven’t added an intake or a turbo inlet pipe, hit me up…there’s power on the table right in front of you.

Jason

Cold Air Induction Box

CorkSport is proud to announce that we are expanding our Cold Air Induction Box product line to include an Air Box for the COBB SF Intake system as well as our current development of cold air boxes for the 2010 Mazdaspeed3 and 2010 Mazda3.

In our testing of this product we wanted to define:

  • Where the cold and hot air fronts exist in the engine compartment and what differential can be expected between these areas.
  • Where high and low pressure areas exist which direct requirements for sealing off areas to ensure the coldest air temperatures into the filter.

To achieve these results, we determined that extensive pressure drop testing under dynamic conditions was not possible while delivering a box that retails under $100. A well planned design of experiment which measured temperatures in the engine compartment, airbox and surrounding areas would give us not only the hard numbers we needed to show results, but also some intuition as to where the various pressure zones exist and how that effects movement of hot and cold air in the vicinity of the filter. What we found is that the various pressure zones in the engine compartment can create barriers preventing the intake from drawing hot air.

Our testing utilized a MSD DashHawk OBD2 Datalogging system and an Innovate TC-4 Four Channel Thermocouple Logger to measure Inlet Air Temperatures, Boost Air Temperatures, Ambient Air Temperature and two channels of thermocouple inside the box and directly outside the box in the hot engine compartment. The ambient air temperature on this day was about 64F. Earlier in the day we tested the short ram intake without our box and found intake air temps were 2-8 degrees lower than the engine compartment temperature.

Testing these variables on our cold air box design we saw a huge benefit – over 30 degree difference between the engine compartment and the interior of the box. By time of this testing, the engine compartment had a chance to heat soak and the hot air in the engine compartment 10-15 degrees higher. Despite this increase in temperature, our average temperature differential was now in the 25-28 degree range and inlet air temperatures were down 8-12 degrees dependent on volume of airflow past the sensor – obviously in traffic you’re going to get some level of heatsoak in the inlet system, MAF Housing, etc. – but that cools off quickly when 64 degree ambient air temperatures blast past at the rate of an office cubicle of volume per minute.

Some may ask, why is your box not enclosed or better sealed within the engine compartment? In the course of our testing seal off surfaces, we found areas – such as the gap under the box – are either a source of cool air or have a pressure effect that prevents hot air from entering into them. Some of these, such as the seams on the box, were beneficial to seal off, some provide relatively cool air, but others were completely inconclusive. Bottom line, there are a number of areas which may appear to allow hot air into the box, but testing proved otherwise.

The end result is a series of boxes which use a overhanging lid with seal strip along the mating surface, silicone seal at the filter port and contoured front edges which align with the headlight assembly. These systems promote filter temperatures roughly equivalent to ambient air temperature and 8-12 degree inlet air temperatures drops compared to similar intake systems without the box. Note: As we did not test at all possible outside air temperatures, extremely hot or extremely cold ambient temperatures may show some variation from these results, but the effects should be minimal.

If you have any questions or suggestions of further tests or concerns you may have with the CorkSport Power Series Intake System or CorkSport Cold Air Induction Systems, feel free to post comments to this blog so we may update the details and content.

Jason

MazdasNW Monthly Meet

I had the opportunity to head out to the MazdasNW.com Wednesday Night meet at Jasmine Grill in Federal Way, WA last Wednesday and I really had a great time. Roughly 70 enthusiasts turned out with 48 Mazdas and a handful of other cars.

MazdasNW Meet
Photos of the event by E. Reyes

Organized by MazdasNW.com, a forum for Northwest Mazda Owners and Enthusiasts, the weeknight meets appear to be just the tip of the iceberg as meets go for this group of enthusiasts of a really wide demographic.

It was great to be out among Mazda enthusiasts and like minded gearheads. The best part was seeing a lot of the custom work people had put into their cars – from custom fabricated dash pods to harness bars. Bringing along the CorkSport 2010 Mazdaspeed3 had some surprising results – mixed opinions abound whenever discussing the 2010 – but one thing was certain, the new Mazdaspeed3 gets attention wherever it goes.

CorkSport 2010 MazdaSpeed 3Photos of the event by E. Reyes

Here are a few photos from the meet. If you’re in the Pacific Northwest, take a look at MazdasNW.com and head out to one of the next meets. The meets are on the second Wednesday of every month, even numbered months at the Southcenter Mall in Tukwilla and odd numbered months at the Northgate Mall in North Seattle. Hope to see you in North Seattle on the 9th of September – go to www.MazdasNW.com for more info.

Click here to see some more photos of the event by E. Reyes

Jason

2010 CorkSport MazdaSpeed 3 Part II

MS3

I was originally going to finish up the rest of the 323GTX adventure but driving the Mazdaspeed 3 made me change my mind.  I decided to do a comparison of the Mazda turbo hatchbacks.  Driving the Mazdaspeed 3 for a week the car is really making me consider getting rid of the other cars I own.  As I drove my 323 GTX to work today for a change, getting into an older car really makes you appreciate the refinement Mazda has put into the new Mazdaspeed 3.

Consider the following, in late1987 when the 323 GTX was new Mazda sold the car for around 16k.  Back in 1988 that was a lot of money for a sporty hatchback.  The 323 GTX was the most advanced hatchback you could purchase at the time from Mazda.  Jump forward 20 years and Mazda decided to go all in on the hotrod hatch market again with the Mazdaspeed 3.  Granted the 2010 model is the refined version and so was the 323GTX when it was introduced to North America.  Little known to some people the 323 GTX had gone through a facelift and revisions from the 1986-87 models to the version we received in 1988.  20 years is a long time in car production so now I will get to the comparison.

Note:  the 323GTX used in this comparison has been modified in about every way possible.  The modifications of the 323 give it a chance against the Mazdaspeed 3 in terms of power and handling despite the 20 year gap in production.

The 323GTX is very coarse in all aspects of the engine.  The boost hits very fast with lots of exhaust noise and the Greddy BOV venting between shifts.  The shifts come up fast too, as the gearing is very short in the transmission.  The Mazdaspeed 3 in comparison the power comes up fast but it is much smoother.  I can give the car some throttle and not worry about the exhaust volume or the venting BOV waking up the neighbors on the way to work at 6am. (I like my neighbors so I short shift it and keep the rpm low.  If you don’t like your neighbors ask me to take the long way to work some morning through your neighborhood)

The Mazdas are pretty close in terms of acceleration.  The 323GTX would take the Mazdaspeed 3 off the line due to the AWD advantage and lighter weight but once you are moving the Mazdaspeed 3 is faster with a higher top speed.

Handling is really close in terms of grip but the Mazdaspeed 3 handles with less steering effort.  I took some local customers for a ride in the car and we left the off ramp on the merge lane to I205 about 10 miles an hour faster than I feel comfortable doing in my 323 with just me in the car.  I had an uneven load of weight in the Mazdaspeed 3 and the car still felt more secure with the extra 175lbs on the driver’s side in the back seat.

The brakes are really no comparison.  The 323GTX did not get the brakes a car like that needed.  The Mazdaspeed 3 on the other hand has massive brakes.
You can tell Mazda spent some time on the interiors of both cars.  The 323 GTX had some of the best production seats ever made in terms of support and comfort.  The Mazdaspeed 3 seats are just as good but will be more durable with leather bolsters.  The Mazdaspeed 3 really shines in terms of how quiet the interior is.  You can drive the car fast and not drown out the screams of the passengers crying “I’m gonna die” in an effort to get you to slow down or not take the next corner as fast.  The layout of the new dash and all of the switch gear placed better and more intuitive compared to the 20 year old 323GTX.

Style of the cars is debatable as well.  The 323 GTX is more of a classic car now so you do not find people being critical of its styling these days.  I am sure back in 1988 there were comments about the two wings on the back hatch and the look of the car from people.  Looking at the 2010 Mazdaspeed 3 the styling is edgy and very forward thinking.  It has some great styling elements which are throw backs to other Mazda vehicles of the past.  The body line on the sides of the car matches the J curve of the door on the 93 Rx7 and the Mx-3.  The hood scoop gives a bit of a nod back to the FC turbo Rx7.  The hatch wing is a tribute to the 323 GTX.  Below is a comparison between the FD Rx7 and the 2010 Mazdaspeed 3 with the J curve highlighted.

MS3

FD

To answer the question of would I really sell off my other cars for the Mazdaspeed 3, this is the first car I have driven that I would trade in my 323 GTX on. Thankfully in this case I didn’t have to make that choice, I get to keep both.

Derrick