Keeping you up to date with the latest CorkSport Mazdaspeed news!
Category: Project Car
CorkSport has a fleet of Mazda project cars, Mazdaspeed 3s of all generations, 3rd gen Mazda 3s including road race cars, FD Rx7s, FC Rx7s, Miatas, and more.
We (CorkSport) showed off our work-in-progress TC America TC Class Mazda 3 race car at the CorkSport Mazda Showdown event on August 5th. If you are asking yourself why this is a big deal and why I am reading a blog post about it, here’s the explanation.
On October 1st, 2019, Mazda announced they would join the TCR ranks with the car attending the 2020 season opener at Daytona with IMSA. The bodywork was excellent; it captured the body lines and presented an absolute WOW factor!
Unfortunately, the car was a no-show at the first round or any round scheduled in 2020. On August 15th, Emily Taylor from Mazda announced they had canceled the TCR program, citing the coronavirus as the explanation.
What About The Body Kit?
So what happened to everything from Mazda’s race program, and why is the bodywork a big deal? There were two sets of original molds made for the bodywork. The 1st set of molds went to the constructor Long Road Racing, and the second set sat at Mazda’s design center in Irvine, California.
The molds in Irvine were the first set made off of TCR “Show Car” bodywork and were not production-ready. The “Show Car” Mazda used for their 2019 announcement and future marketing campaigns wasn’t an actual race car. It was a production car with the bodywork on it, but the engine & drivetrain was stock.
CorkSport has been racing a 3rd generation Mazda 3 in the TC class for several years as the development tool for the Skyactiv Turbo kit we offer.
When running in a professional series, the series works with manufacturers and wants the newest models competing on the track to keep the series fresh and relevant for marketing for both the auto manufacturer and the race series. The last 3rd Gen Mazda rolled off the production line in early 2018, making our race car over a year old when the TCR program was announced and over two years old when the program was canceled.
We needed to race the 4th Gen Mazda 3s to keep competing in TC America,
The Journey For the Mazda 3 TCR Kit
This may seem like an exaggeration, but I spent over 200 hours on the phone, in meetings, writing emails, and talking with employees, ex-employees, and contractors that Mazda used to chase down where the bodywork went, who was ultimately in charge of it, and to see if we could get our hands on it.
Once I knew the molds still existed, additional meetings, phone calls, and emails were required before signing an, “OK, we will consider it. Your plan and history jive with a company (CorkSport) that can use the parts and provides a benefit to Mazda.” type of agreement. During this time, I learned the first set of molds had been destroyed, making the motorsports molds the only set left.
In October 2022, snagging the TCR bodywork molds became a strong possibility. I was headed to Texas to drop off some racing equipment to a friend. I decided to leave my truck and trailer in Texas since the bodywork molds were now located on the East Coast. If Mazda agreed we could pick up the molds in the next few months, the truck and trailer would already be halfway there.
December 12th, 2022, Mazda gave me the green light to gain access to the molds after several more phone calls, ZOOM meetings, and agreements were made. I flew back to Texas and headed to Multimatic in Mooresville, NC, to complete this epic quest. After one very long drive, including a massive ice storm, and making it home on Christmas Eve, Mazda’s TCR molds were at CorkSport.
Since then we have been planning and slowly building the new TC Car – We cannot thank Mazda Motorsports enough for choosing to partner with us as we continue to shape our racing program!
The body kit is thick and the ride height was not adjusted prior to the reveal .Rear wing is not to racing spec and was added temporarily to represent what it might look like in the future – rear window will eventually be plexiglass.
Are These The Real Thing?
A common question that will get asked is, “I have seen the Mazda 3 TCR kit overseas, how is what you have the real thing?” Well, my friends, Technology and replication are a wonderful thing.
I asked the same question about the hill climb machine that TCP put together for Mike. If you compare the kits, you can see there are some differences in the kits with the aero, brake cooling, grill area, and more.
It was unofficially stated there were body scans done of the show car with Mazda Japan and those are the results. I cannot speak about the Thailand car but a handheld scanner and some import auto salon are my best guess.
Look forward to more updates on our build over the next several months, This is going to be fun!
Welcome to part 4 of the Mazdaspeed3 AWD Swap! If you missed the previous posts, you can catch the Intro, (Part 2), and Part 3. This blog will cover the rear suspension design, specifically the rocker arms, and how we came to the size, shape, and overall design. This will get technical with numbers, angles, and CAD models.
Before we get into the technical jargon, let’s cover the “what” with rocker arm suspension.
Mazdaspeed 3 AWD Swap Rocker Arm Suspension
Let’s break down this diagram as it is 100% not OEM for the Mazdaspeed 3:
Rocker Arm: This is the keystone of the suspension design and does all the work. The rocker arm connects the push rod and the damper to transfer suspension force at a different angle. The rocker arms can also go by a few names: rocker arm, bell crank, cantilever, and pivot arm, to name a few.
Push Rod: This is a simple rod with spherical rod ends on each end. This connects the OEM suspension to the rocker arm. The push rod is in a similar location as the OEM suspension.
Suspension Mounting Bracket: This is the mounting point for the push rod to the OEM suspension trailing arm. This must be added because the OEM damper mount is below the now-new axle shaft.
Coilover/Damper: This is an off-the-shelf damper that can have a coil spring installed on it. It features independent rebound and compression damping adjustability.
Cross Member: This is the cross member that is welded between the chassis shock towers in the car to support the new rocker arm suspension.
Here you can see the design tack welded in the car. This should help you understand how the design fits and is used in the car itself.
Mazdaspeed AWD Suspension Corss Member TackedMazdaspeed AWD Suspension Push Rod Mount
Now that we have a basic understanding of this rocker arm-style suspension let’s get into some more details!
First, let’s talk about suspension and the forces they deal with. Gravity pushes you and your car down to the ground, and road imperfections (bumps, potholes, unlevel surfaces) try to push you and your car up/down/all around while driving. If vehicles did not have suspension and instead the wheels were rigidly attached to the vehicle chassis, we would have all sorts of issues. Comfort, control, and tractions are the big concerns, amongst many others.
The suspension’s job is to soak up and move with many road imperfections like bumps, potholes, and unlevel surfaces. Every time your tire goes over a bump or pothole, it moves up or down, resulting in a force transferred into the suspension.
Check out this quick illustration to see the rocker arm suspension in motion:
As the tire moves up/down, you can see that the rocker arm pivots and transfers that motion into the coilover/damper.
Now let’s break down those forces a bit more. The rocker arm allows us to change the angle of the forces transferred to a new angle that is easier for us to deal with. Instead of being required to have a coilover/damper in a vertical suspension down around the tire (like OEM), I can now change the angle so I can put the coilover/damper in a position that is much easier to deal with.
Rocker Arm Suspension Mazdaspeed Swap Forces
The rocker arm has two major features about it.
The angle change of transferred forces, as we just discussed. This is mainly to help with “positioning” the suspension components.
The rocker arm lengths allow us to define the “motion ratio” of the suspension. Looking at the diagram, you can see a blue line and a green line. These effective rocker arm lengths affect the suspension and result in a motion ratio.
The resulting ratio is 1:0.7 meaning the damper compresses 70% of the amount that the wheel moves up/down.
The wheel/tire has a maximum range of 5.55 inches of travel, while the damper has a maximum travel of 3.875 inches.
Designing the rocker arm with this 1:0.7 motion ratio allowed me to use a smaller, lighter damper design with limited travel and still get the desired wheel suspension travel I needed. We use a stiffer spring to compensate for the extra leverage of the motion ratio.
Motion ratios in suspension are common. For example, the Mazdaspeed 3 suspension has a unique motion ratio in the front (1:0.98) and rear (1:0.71) from our calculations. These numbers are typical of the style of suspension found in many commuter cars these days.
Now that we understand the forces and the intent with the rocker am…we have to design its shape and size to do the job. Angles are the tricky parts of the rocker arm design. Defining the angles (and thus shape) comes down to understanding the push rod input angles and the desired damper output angles while in motion.
Rocker Arm Suspension Mazdaspeed AWD Swap Angles
When we say “angles,” we are talking about the red arrows in the above diagram. These red arrows are the angles between the rocker arm and the push rod, as well as the rocker arm and the damper. Ideally, these angles are always 90 degrees through the entire motion you see in the GIF, but that is not physically possible, so we had to find the correct balance of angles while in motion.
A whole lot of math encompasses this, but the upcoming diagrams will help break it down to a very understandable level for everyone! We are breaking it down to the three major suspension travel points: droop, bump and ride height.
First, we are going to look at the angles for the push rod in Bump, Ride Height, and Droop.
Bump is when the suspension is fully compressed.
Ride Height is when the car is sitting stationary (static).
Droop is when the suspension is fully decompressed. Image your car sitting on jack stands with the tires hanging in the air.
Mazdaspeed 3 AWD Rocker Arm Angle Bump Pushrod
In full bump, the push rod angle to the rocker arm decreases to 67 degrees which is 23 degrees off the “ideal” 90.
Mazdaspeed 3 AWD Rocker Arm Angle Ride Height Pushrod
Then looking at ride height as the suspension moves downward from full bump. The damper-to-rocker arm angle decreases to 82 degrees which is 8 degrees off the “ideal” 90.
Mazdaspeed 3 AWD Rocker Arm Angle Droop Push Rod
Lastly, with the suspension traveling to full droop. The push rod to rocker arm angle increases to 117.5 degrees which is 27.5 degrees off the “ideal” 90.
What does this mean? This is great, actually! Ride height is where the suspension will function most of the time, and that is only 5 degrees off the ideal 90-degree angle. When the car is launched in a drag race, the suspension is going to compress, and that angle will decrease, passing through the ideal 90-degree angle and further. This is precisely the balance we are looking for with the rocker arm design. To keep it functioning most of the time as close to 90 degrees as possible.
Ok, let’s look at the angles from the damper side of the rocker arm.
Mazdaspeed 3 AWD Rocker Arm Angle Bump Damper
In full bump, the damper angle to the rocker arm increases to 111.5 degrees which is 21.5 degrees off the “ideal” 90.
Mazdaspeed 3 AWD Rocker Arm Angle Ride Height Damper
Then looking at ride height as the suspension moves downward from the full bump. The damper-to-rocker arm angle decreases to 82 degrees which is 8 degrees off the “ideal” 90.
Mazdaspeed 3 AWD Rocker Angle Droop Damper
With the suspension traveling to full droop, the damper-to-rocker arm angle decreases to 62 degrees which is 28 degrees off the “ideal” 90.
Again we have the damper near the “ideal” 90-degree angle at ride height and then pass through the 90-degree angle zone when the suspension compresses at launch. Again, the balanced angles we are trying to design for so the suspension function in the “ideal” angle range most of the time.
Why are the angles so important? The further you get from the “ideal” 90-degree angle, the more non-linear the suspension acts. When the suspension acts in a linear function, it is tunable and predictable to drive. If it is non-linear, then it makes tuning and use much more difficult…this results in inconsistent launching and driving, which is not good in a racing environment.
Mazdaspeed AWD Swap Racecar Suspension
This seems like a lot of work…why do it?
A few reasons, really:
Moving to the rocker arm design gave me a lot of control over how I set up my Mazdaspeed for racing.
It also gave me the ability to use readily available off-the-shelf dampers. This allowed me to get double adjustable dampers (rebound and compressor) for a very cost-effective price.
The CX7 AWD swap rear axle shafts did not allow me to use the OEM dampers anyways.
This design moves more of the suspension component’s weight to “sprung mass” which is better.
I love the challenge of designing a suspension system like this, and this was a great opportunity!
Before we wrap things up, note the rocker arms are 6061-T6 billet and are massive! We knew they were big, but it didn’t really sink in until we saw them firsthand.
Rocker Arm Size ComparisonRocker Arm Size Comparison 2
Alright, that wraps up the rocker arm suspension design, a huge novelty for the build. There are plenty more huge milestones to overcome, and those are coming up in this multi-part blog series!
I hope you are enjoying this series about the AWD Swap Mazdaspeed3, stay tuned for more blogs to come!
Have you ever felt like you try and try and try, but just can’t get the traction to make forward progress on your Mazdaspeed 3 car build? Ya, it happens to the best of us and the 2022 season was my time…both in literal traction and life.
If you haven’t seen my build yet, the @halfmilespeed3, go check it out. It’s an awesome combo of DIY, Teamwork, Innovations, and CorkSport goodies you all love.
Back to this traction conundrum. Racing an 800+hp FWD Mazdaspeed 3 on small airport airstrips with no prep and plenty of dust has proven to be challenging. There have been many successes and many challenges, but ultimately it comes down to those two tiny patches of rubber that meet the road.
LITERALLY NO TRACTION
Yes, Motec helped substantially with traction control and Justin’s ramp-up in power delivery also helps, but really…I just didn’t have any damn traction. Sticky tires with meaty sidewalls also help, but again traction was such an issue! There had to be a better way!
Wheel & Tire Setup:
Front: Toyo TQ 255/50 on 16×8+38
Rear: Toyo R888R 255/40 on 17×9+45
And there was and I had been talking about the idea for a year or so already. Then life happened.
As you can see with the racecar; I like to go fast. I carried that enthusiasm into my love of mountain biking one day in June 2022 and well…I got a lesson in physics let me tell you.
Five broken ribs, a double punctured lung, level 3 AC separation, and a fractured collar bone and scapula. Resulting in weeks of hospital stays and three surgeries; then months of recovery and physical therapy. Let’s just say the 2022 season did not go as planned.
But it did get me focused on solving my traction problems…
Mazdaspeed 3 with CorkSport Mazda Performance Parts Back (AKA HalfMileSpeed3)
The Goal…Mazdaspeed 3 AWD Swap
So I decided it was time to stop talking about it and actually take action (well as soon as I physically could that is). I made a plan and figured out the details and order of operations to finally get my traction back.
While I am not the first to do a Mazdaspeed AWD swap. I did have a goal to make my build unique in the sense that the AWD swap is catered to racing performance. Meaning the strength of custom parts and the rear suspension design and the new fuel system are capable of handling the 4-digit horsepower goal I have and the abuse of racing.
Talking horsepower…what does the car make right now?
This is at a modest 40-41psi using a Xona Rotor 9569s with the X3C compressor housing and 1.03A/R turbine housing. Later Justin @freektune and I turned it up a bit more to see how close we can get to the 600wtq threshold and hold it. Clipping off an 881whp run…damn! This was supported by the many CorkSport Mazda performance parts you can get for your Mazdaspeed as well. From engine mounts to manifolds, anything that isn’t a one-off custom is CS.
Anyways…I have since updated the compressor wheel to a 99 lb/min design compared to the above 95 lb/min design and a larger compressor housing which is more efficient. This setup has not been dyno tested yet, but talking to the engineers at Xona…2023 is going to be spicy!
Close up because who doesn’t like billet turbo shots!?
Dare I say this is the largest turbo in the stock location ever on a Mazdaspeed? Go ahead…prove me wrong. To compare, this competes with a Precision 6870.
The Start of the Mazdaspeed 3 AWD Swap
Anyways, this is the introduction to my Mazdaspeed 3 AWD swap here at CorkSport HQ. I actually started the swap in October 2022 and have been making big steps each month. We are going to be sharing blog updates rapidly as I wrap up the swap over the next couple of months.
There will be much more technical info and images coming up so grab a drink and enjoy!
You can also find updates on my IG @halfmilespeed3, the CorkSport 7th Gear Membership, and on mazdaspeeds.org.
Putting a turbocharged engine in the GEN4 Mazda 3 was a step in the right direction for Mazda but it still misses the mark of a “hot hatch”. Well, that’s where we come in! Introducing the CorkSport Lowering Springs for 2021+ Mazda 3 Turbo. We took what we learned from the naturally aspirated Mazda 3 and applied it to the slightly heftier turbo models. This resulted in a great new ride height and improved handling to push the GEN4 closer to a hot hatch, without ruining the daily driving comfort. Read on for full details and images of the great new look!
Let’s start off with what everyone wants to know: ride height! With only one driveline & transmission option, we could really dial in the ride height for both turbo hatchback and sedan models. The CS lowering springs for the turbo models offer a similar ride height drop to the N/A models. For the turbo hatchback, this means a ride height drop of approximately 1.5” in the front and 1.8” in the rear. For the slightly heavier turbo sedan, expect a drop of 1.5” in the front and 1.9” in the rear. While the sedan is a slightly larger drop in the rear than the hatchback, it still sits level and looks great!
Stay Up-to-date with CorkSport
This ride height is low enough to look great yet not too low to cause you issues on your daily commute. We found that this ride height can clear most driveways and speed bumps no problem. On really steep driveways, taking it slow and at an angle will help you keep your front bumper safe. We haven’t really found a driveway that was an issue though! One final note: we did test our regular, non-turbo Mazda 3 lowering springs on a turbo car. While they fit, the extra weight from the turbo system had the car sitting way too low in the front & looking ugly. We would not recommend doing this!
Moving on to the next best benefit from lowering springs: handling! The CorkSport lowering springs offer some much needed sharpness to the MZ3-T. By lowering the ride height, you lower the center of gravity of the vehicle. Combining this with stiffer than OEM spring rates, body roll is reduced, which greatly helps driver confidence through the twisties. We carefully chose our upgraded spring rates to also help reduce understeer when at the limit of traction. By increasing the rear spring rate more than the front, your turbo 3 gets better turn in and more neutral handling.
The final spring rate numbers for the Mazda 3 2.5T lowering springs actually surprised us. We tested a few different spring rate combinations to find the best balance of ride and handling. Ultimately, the same spring rates as the naturally aspirated Mazda 3 won out (this was due to both cars using the same suspension design). A 3.4K front spring and a 5.9K rear spring offered a compliant ride for daily driving, yet great handling characteristics on a backroad. The OEM dampers on the turbo models are just a hair stiffer as well, so the increase in spring rate fits fantastic with no bouncy ride!
Each set of CorkSport lowering springs for Mazda 3 turbo are made specifically to fit directly in place of the OEM springs. The only small modification that is needed is to trim the bump stops to allow for correct suspension travel before the bump stop is contacted at the new lower ride height. The springs are all made from high-tensile strength spring steel. This ensures a consistently performing spring that will stand the test of time and will not settle. We finish off each spring with a powder coated red finish. We chose red instead of the typical CS blue to help the turbo models stand out and because red things are proven to go faster! We even include a spring silencer on the rear springs to prevent any noise.
That about wraps up the launch of the CorkSport Lowering Springs for Mazda 3 Turbo. Check out the product listing at the link below for more pictures. Be sure to give us a call with any questions you have, we’re happy to help!
P.S. The car in the above images is riding on Advan GT wheels in 19×8.5 +38 size, wrapped in Kumho 235/35 R19 summer tires.
Stickers are worth 5hp right?…So it was only logical to wrap the whole car in a GIANT sticker! Anyways, on a real note we knew that the @Halfmilespeed3 couldn’t just be fast, it had to look good and what Car Guy or Gal doesn’t want their car to look good?
We have a plan at CorkSport to wrap all of our R&D Shop Cars with an awesome blue that aligns with our “CorkSport Blue”, but we want each car to have a little unique character to it. Thinking about the halfmilespeed3 build and goal we had the brilliant idea of a split wrap…seems fitting right? Half and Half…
So what did the car look like before the wrap?
Metro Grey Mica is the color name and its pretty bland in my opinion. I added the white roof and hood accents along with white wheels to help brighten up the car, which it did, but it was time for change. Oh yeah; white wheels and track spec brake pads don’t mix, just an FYI.
So what is like to get your car wrapped? What’s the process? I can’t personally give you details as I did not do the wrap myself, but I was close to the action and watched it all come together. Respect to those that take this on themselves and to the professionals out there. It is a tedious process that requires attention to detail to get a great final result.
A local friend is a professional and was open to doing the work in the CS shop since the Speed was not in a running and driving state at the time.
Saul S. (@saulywood) did the work over a few weeks’ time in evenings and weekends. He kicked a** on a project that turned out to be a bit more difficult than expected.
Installing a wrap is a process of pulling, stretching, heating, cutting…lots of different skills and abilities to get the job done. All this has to happen without damaging the vehicle you are wrapping. It’s quite a feat.
Going through the process the build kind of evolved if you will. Luckily Saul was very open-minded to it and even a bit eager to try some new things.
Probably my favorite aspect of the wrap is the unique and new wrap from 3M. Called “Shadow Black” this wrap has a slight texture to it that depicts patterns sort of like camouflage.
We used this on the roof and in a narrow strip over the seam between Satin Black and Blue Gloss; it really added a unique aspect to the look and style and brought the two colors together. Pictures just do not give it justice nor can you feel the texture.
So let’s wrap this up (see what I did there?) with some finished images.
I have to admit I’ve fallen in love with my car again. The exterior of my car was pretty beat up and neglected with rock chips, scuffs, and just generally not well taken care of paint. With the new wrap there is a whole new rush of pride and enthusiasm to keep it looking amazing.
Lastly, and this is bit cheesy, I requested Saul to match my helmet to the car…
Why not right? It’s not just another black helmet and I love it.
With that I hope you enjoyed this sneak peek into wrapping a Mazdaspeed. Stay connected as we share more and more about the @halfmilespeed3 build…engine, seats, roll-cage, and power! At some point this season an event will open and we can actually race!
