3rd Time’s the Charm…Racing at the SCCA Nationals

We all know the saying the 3rd time is the charm and this yearโ€™s SCCA National Championship Runoffs was no exception to the rule. ย The past 2 runoffs I have not made it to the finish line. ย In 2016 at Mid-O I was hit on the first lap and punctured my left front tire. ย At Indy, I retired as we developed a fault in the ECU from some beta software we were running and the car dropped into limp mode and I wasnโ€™t able to maintain full throttle. ย 

We have been working on the brakes for the past 3 years and during the season it limited us from running the car as much as we like. ย We have also been chasing a fault/error with the ECU/control system of the car. We were still able to get the car enough starts and race finishes to get qualified for the runoffs in Sonoma. ย ย Granted the car was not happy at most of those races and it was a struggle to get to the finish.

2 weeks before the runoffs we sorted out the ECU problem and were confident enough in the car to race it. ย The backup plan was to race my Spec Miata if we couldnโ€™t get the Mazda 3 fixed as I ran it this past season as well and had enough starts/races.

With the Runoffs at Sonoma, it was within 1-day driving distance unlike the past 3 runoffs at Daytona, Mid Ohio, and Indy so I got to try out the new (to me) truck and trailer.

I had raced at Sonoma one time prior,ย so the track wasnโ€™t totally unknown like Mid-O and Indy, which all I had was simulator time so I was able to get up to speed quickly on a test day and find out what I needed to work on for chassis setup and driving. ย The driving was easy to adjust, look at the data, see where the driver was sucking, and had to man up to keep a foot to the floor in some sketchy corners.

The car, on the other hand, had what we call “a good problem to have”, too much power. ย We have been running a torsion-style differential in the car which works pretty well in a straight line and relatively flat tracks. ย Sonoma is not a flat track that unloads the car 3-4 times per lap. With the Mazda 3 and the amount of torque, it makes means I was unloading the tire enough for it to spin the inside tire. ย Most people think what is the big deal with a little tire wheel spin? It is a problem when you enter turn 10 at Sonoma at 97MPH and you start lighting off your right front tire. Look at the picture below and you can see that the front inside tires are barely on the ground and the rear isnโ€™t. ย The speedometer would jump around and you could see the right front wheel speed turning at 5-10 mph more in the data.

Mazda CorkSport car racing

We tried several suspension changes and driving style changes to make the best of it but in the end, we were way off the pace by 2-3 seconds of the rear-wheel drive cars in the class.

The good part about not being at the front of the field, there was zero stress when race day came.

Like any race there was a fun challenge, we would be heading into turn 2 blind as the race was at 4 pm in the afternoon and the sun would be shining directly down the hill. ย Since I wanted to see the end of the race I was a little cautious at the start and Ali in the other Mazda 3 got around me at the start.

We fought it out for 8 laps and he went into turn 6 too hot and I was able to get under him and pass him on the inside.

After a few laps I put a 4-5 second lead on Ali I was basically in no manโ€™s land, slower than the front guys and faster than the back half of the field so I spent my time working on tire management (it is easy to overheat your left front tire at Sonoma) and made it to the end of the race.

My official finishing place was 10th but after some adventures in tech, I was moved to 9th in the final results.  This isnโ€™t where I wanted to be by any means but the 3rd time was the charm and I made it to the end of the race.

Huge thanks to the support we get racing the car from CorkSport, BFGRacing, Monarch Inspections, G-Loc Brakes, and Mazda Motorsports.

Derrick Ambrose

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Exhaust Scavenging Designed with The Exhaust Manifold for Mazdaspeed

In this blog, we are going to SHOW a demonstration of exhaust gas scavenging.  Instead of a lengthy blog full of text, weโ€™ve opted to create a video that demonstrates the effects of exhaust gas scavenging for both good and bad designs.  

We will be comparing the prototype CorkSport performance exhaust manifold, developed for the Mazdaspeed 3 and 6, to the OE exhaust manifold.  

Exhaust gas scavenging within a manifold is the process of one cylinder runner, pulling (aka scavenging), the exhaust gas from an adjacent cylinder in a continual cycle.  Now enough talk, to see an awesome example and an awful example of exhaust gas scavenging check out the video below. BONUS! Not only do you get to see what optimal scavenging looks like, but this is also the first sneak peek of the CorkSport Performance Exhaust Manifold

Video Link: https://youtu.be/RtydboDbwpQ

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We hope you found this as interesting as we did!  Stay tuned as we continue developing the CorkSport Performance Exhaust Manifold for the Mazdaspeed platform.

-Barett @ CS

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Safely Upgrade Your Mazdaspeed Turbo

It doesnโ€™t take long for those building power to use up the stock Mazdaspeed K04 turbo. They are prone to fail, especially when you start shoving that extra air through it. A common question is, โ€œMy Mazdaspeed is smoking, is my turbo bad?โ€

First things first. There is a BIG difference between replacing a bad turbo and upgrading Mazdaspeed K04 to a more efficient one for more power. If you want to replace it, go with OEM and just plug and play, youโ€™re good to go, wash your hands, and get on with your life. This will have your car up and running pretty quickly. However, your maximum power output will be limited and you will eventually have the same problem – the Mazdaspeed KO4 turbo will fail.

If you are saying to yourself, โ€œItโ€™s time to upgrade the K04 Turbo…I NEED more power in my life!โ€ Then this blog is for you. Below, we lay out the basics needed to successfully install a CorkSport Mazdaspeed Turbo, highlighting the required supporting modifications to keep your Mazdaspeed safe. As a bonus, we keep our installation instructions on each of our product pages, so you can preview how easy the installation will be for your experience level.

Mazdaspeed Turbo Upgrade for the K04 BNR

Here it is, the list is comprised of the BARE essentials to run the 18G CorkSport turbo.

HPFP INTERNALS

Giving you 50% more efficiency with your fueling system, as well as, a strong base to build power for your Mazdaspeed. The CorkSport Max Flow Fuel Pump Internals are built to directly replace your stock fuel pump internals and perform with immediate improvements.

CorkSport fuel pump vs. competitors

ACCESSPORT (or VERSATUNE if you have a CX-7)

The Cobb Accessport will give you the basis for tuning, and since this is required with the CorkSport turbo – youโ€™ll want to make sure you have this in hand and ready for when you install your turbo.

These are the basic foundations of our Mazdaspeeds, without these two items you cannot operate your Mazda after installing an upgraded turbo.  You will need your Mazdaspeed tuned, and your tuner is going to say the same thing.

Thatโ€™s it, thatโ€™s all you need to run the CorkSport Mazdaspeed turbo safely. With this proper foundation, you can put yourself in a position for efficiency, or more power.

Mazdaspeed turbo upgarde and installed on a Mazdaspeed 3

Now the question is do you want to make it go fast and harness the power that this turbo is built for? Keep reading and weโ€™ll provide some other awesome upgrades that are the next step once you have your turbo installed and running.  Oh, and if you are looking for a proven path to make 400WHP, check out our Chasing 400 WHP Blog here!

2013 Mazdaspeed 3 Engine bay with TMIC, SRI and Turbo inlet pipe, CST4

CorkSport Upgraded 3.5โ€ Intake

The CorkSport turbo is rated for up to 450WHP with the right set up. Unless you are going for the MOON and shooting for over 700WHP a 3.5โ€ intake will be more than sufficient for this turbo. Giving you some extra airflow to increase your power range, and harness what your Mazdaspeed3 is capable of. Note: Will require additional tuning!

Mazdaspeed 3 Turbo Back Exhaust

CorkSport Mazdaspeed Downpipe

Doesnโ€™t matter if you go with a high-flow catalyst or opt-in for one without, the choice is yours. However, if you want to utilize its flow you are going to have to upgrade to a bigger diameter. Our 80mm one does really well, plus it sounds GREAT.  Note: Will require additional tuning!

CorkSport Cat Back Exhaust for Mazdaspeed 3

CorkSport Cat-Back Exhaust

Itโ€™s no secret that car engines are just big air pumps; the faster you can shove air into the engine and the faster you can expel it efficiently is what it takes to make more power. No need to run the stock 63.5mm Mazdaspeed exhaust when you can run our 80mm (like to wake up the neighbors every morning, go with our non-resonated, you canโ€™t beat the cold start)

Top Mount intercooler for the Mazdaspeed comparison OEM vs CorkSport

CorkSport Top Mount Intercooler

If your power goal is 450whp or less you can get away with just upgrading your TMIC and be on your way and they look great in your engine bay.  Note: Will require additional tuning!

If you have the 2nd gen you can really utilize that hood scoop from the factory.  Not only that but you can even see a noticeable performance gain with our larger hood scoop and a TMIC set up.

When it comes to your Mazdaspeed we know you want to create safe power and harness the true potential of your ride. Be sure to build upon the proper foundation and head in the right direction for your build. Our techs are available for any questions you have and are ready to assist with planning your Mazdaspeed build path! Any questions – give us a call directly – (360)260-2675, email to sa***@*******rt.com or leave a comment and weโ€™ll get back to you!

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Mazdaโ€™s Dynamic Pressure Turbo โ€“ A Closer Look

There has been a lot of buzz about the new(ish) turbocharged SkyActiv-G 2.5L first found in the Mazda CX-9 and now in the Mazda 6. ย Along with all this buzz, there are a lot of unknowns as well. Here at CorkSport, weโ€™ve taken the step to try and address some of these unknowns. ย What is Mazdaโ€™s โ€œDynamic Pressure Turboโ€ and how does it work? There have been diagrams bouncing around on the internet, but no close-up view of the turbocharger itself. ย Thatโ€™s about to change.

Mazda 6 Turbo

If you haven’t already read Daniel’s first installment, “Mazda Dynamic PressureTurbo an Introduction.” You wouldn’t want to miss out on the extra information before reading on.

Mazda 6 Turbo

The turbocharger found in the 2.5T equipped CX-9 and 6 is quite complex in design.  There are many aspects to the OE turbocharger we could discuss, but today we are going to focus solely on the dynamic pressure system and turbine housing.  

If you are reading this, then youโ€™ve probably already seen various diagrams depicting how the dynamic pressure system works and showing Mazdaโ€™s clever 3-2-1 exhaust port design.  If you havenโ€™t, check it out below.  Image credit to Car And Driver Magazine for the fantastic diagram.  

The Mazda Turbocharger 4-3-1 design

Mazdaโ€™s 3-2-1 exhaust port design takes full advantage of the engine cylinder firing order. ย The advantage is improved exhaust gas scavenging for the adjacent cylinder (more or less the cylinder that just fired helps pull the exhaust gases out of the next cylinder that is about to fire). ย Ok, moving on; this is great, but how does the dynamic pressure system come into the mix?

Mazda 6 Turbo Skyactiv design

Shown here are the turbocharger assembly and the dynamic pressure valve assembled as one unit (the first two images also showed the fully assembled setup). ย The three ports are clearly visible along with the โ€œvaneโ€ that passes through the three ports. This vane rotates depending on the engine RPM to control the exhaust gas velocity entering the turbine housing. ย The vane itself is controlled by the larger blue-colored actuator.

Mazda 6 Turbo design for exhaust  velocity

Now letโ€™s take an even closer look. ย The vane does not open until approximately 1600rpm, but the engine cannot run if there is no exhaust gas can flow out of the engine. ย To resolve this Mazda has designed a dynamic pressure system with two exhaust gas paths. ย Looking at the above image you can see a small opening just above the vane. This is the sub-1600rpm exhaust gas path. ย 

By reducing the cross-sectional area of the exhaust gas path, the exhaust is forced to accelerate through the dynamic pressure system and into the turbine wheel.  This effectively reduces turbo lag, improving the vehicle’s response at low engine RPM. Once the engine revs past 1600rpm the vane opens, allowing the larger path to be used.   

Mazda 6 turbocharger

Here we show the turbocharger assembly (right) and the dynamic pressure valve assembly (left) separated.  Looking at the dynamic pressure valve assembly, you can now more clearly see the three small paths above the larger path with the vane inside.  Then look at the turbocharger assembly and you will see the small upper path and the larger lower path.

The fact that these two assemblies are separate systems is great news for the enthusiast.  The development of a performance turbocharger will be much more feasible and the dynamic pressure valve can be retained with the performance turbocharger.  One more detail to point out.

Mazda 6 turbocharger design for exhaust pressure

Mazda put a lot of thought into the design of the wastegate port; let me show you why.  First, looking at the inlet of the turbine housing you can see a small vertical wall in the large path.  This wall creates a completely separate path to the wastegate port which is very unusual on an OE turbocharger. Combine this design with a very large wastegate port and you get a design that can โ€œwasteโ€ or divert an excessive amount of exhaust gas.

Mazda 6 turbocharger design for skyactive-g 2.5l

This tells us the SkyActiv-G 2.5L engine is creating a lot of (currently) unused exhaust gas energy.  Again this supports the feasibility of a performance turbocharger suiting Mazdaโ€™s new turbo engine quite well.  

Great things are on the horizon for the Mazda 6, now if only Mazda would put this engine in the 3 paired with a 6-speed manual transmission. ย Oh, one can dream.

-Barett @ CS

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CorkSport and Mazda Events

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

August is kind of a sad month if you look at a calendar. ย 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. ย But, look no further than the CorkSportโ€™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. ย Be sure to let them know if you are coming on their EVENT PAGE!

Oh, you forgot who I am. ย Well, I put on one of the craziest meets for us Mazda junkies. ย 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. ย You might be wondering what that has to do with a Corksport Dyno day? I will gladly tell you.

Corksport has gotten behind Mazdaspeed Idahoโ€™s little shindig in a big way. ย ย You see, the good folks over at CS year after year make the trek, a pilgrimage if you will to Idaho for Takeover weekend. ย 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. ย 

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. ย 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 theย  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. ย 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. ย Which is what Mazda should be about, forming and building a strong, unbreakable community that forges lifelong friendships through one shared passion. ย 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. ย 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