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Performance Parts for the 4th Gen Mazda 3

Today we are going to lay it all out; we are going to tell you about what we are working on for your Mazda 3 and WE ARE EXCITED!  Who are we?  If you don’t know already, we are CorkSport Mazda Performance based out of Vancouver, Washington.  We are the number one Performance Aftermarket Mazda Parts Company and we have set our sights on the 4th Generation Mazda 3.

Below are the first projects we are developing for the 4th Gen Mazda 3 and CX30.  Engine performance, suspension performance, and styling are all covered here and we are closer to launch than you may realize.  Sit back and enjoy, there’s a lot here and we want you to see it all. 

White 4th Gen Mazda 3
CorkSport – Lowered on CS Springs

One of the most sought-after and anticipated performance items for the 2019+ Mazda 3 are the CorkSport Lowering Springs.   The CS springs provide the most aggressive drop on the market today while providing a sporty and comfortable ride for daily driver use.  With that, we have confirmed fitment on FWD manual transmission hatch and AWD automatic transmission sedan.  We found that the Auto AWD Sedan rides just slightly lower, but is still within proper ride height for suspension function.

Blue CorkSport Mazda 3 lowering springs
See all of our Lowering Springs

We design our springs with more than just looks in mind (but they do look great).  Spring rates and suspension frequency are critical to performance and comfort.  With that being said we increased the front spring rate 52% and rear rate 40% based on the OEM 2019 FWD Hatch MT springs.  

Mazda 3 Hatch Back stance with lowering springs
White Mazda 3 Rear Stance with Springs and Axle Back Exhaust

Now if you’re looking at the images and thinking “Damn those wheels look good” then you are correct and we agree; they look amazing and fit the car and CorkSport springs perfectly.  

Here are the specs: Advan RS 19×8.5 +38 with 235/35 Kumhos.  We have just the slightest rub on the inner fender on large bumps.  Besides that they are perfect and you can have this setup too!

Best 2019+ Mazda 3 Axle Back Exhaust
See all of our Axle-Backs

Next up is the CorkSport Axle-Back Exhaust.  Off the showroom floor, the Mazda 3 is ghostly quiet which is pretty disappointing. Our goal with the Performance Axle-Back Exhaust is a noticeable but mellow tone that you can enjoy every single day; gents this is Wife/Girlfriend approved. 

Red Mazda 3 Sedan
CorkSport – Using OEM Springs

We are proud to announce that will we be supporting multiple models on launch.  We have confirmed the Sedan, Hatch, Hatch w/Aero Package, and the CX-30.   Along with that we have confirmed fitment for both FWD and AWD models for all cars listed.  

See all of our Strut Bars

Look closely, there are a couple new products in this engine bay…long in development is the Short Ram Intake System which replaces the OEM airbox with a high flow dry element filter, billet aluminum MAF housing, 4-ply silicone coupler, and stainless steel T-bolt clamps.  

Upon launch we will be offering various color combinations between Black, Red, and Blue.  You can see them below.   

Mazda 3 Short Ram Intake System
See all of our Intakes

In our testing we have seen repeatable 5whp gains at peak with a nice increase across the RPM range.  Street driving our butt dyno agrees with crisp throttle response and a lovely intake induction noise.  The combination of induction noises, exhaust note, and sporty feedback from the sport springs really turns the Mazda 3 from an A-to-B car to a great enthusiast hot hatch.  

Mazda 3 with CorkSport products installed in engine bay
Mazda with CorkSport Products

The other project sitting in the engine bay is the CorkSport Front Strut Brace.  Bracing the strut towers to each other improves chassis stiffness and reduces suspension complicity.  This results in increased driver feedback and thus a better driving experience.  The powder coated steel brackets and polished aluminum cross bar add a nice loot to the engine bay.  

Rear sway bars designed for the 2019 Mazda 3
Click to See all of our Swaybars

Lastly, and still in development, are the rear sway bars for the FWD and AWD 4th Gen Mazda 3.  This project has been interesting because of the new torsion beam rear suspension found on the 4th Gen Mazda 3.  It’s interesting because there is no factory equipped sway bar.  Instead of just developing a larger rear sway bar, we are developing a sway bar from scratch along with the attachment methods.  

You also notice that there are two different bars in the image.  This is because the AWD and FWD torsion beams are different due to the AWD drivetrain.  Long story short, we are developing a RSB for each drivetrain specifically because that’s the correct way to do it.  

Wow, that was a lot, and trust me there is more we are investigating, but we can’t let ALL the secrets out yet.  We would love to know what products you would like CorkSport to develop for the 2019+ Mazda 3 platform, you can do so right here by Submitting a Product Idea.  

Also, we love sharing with the community directly and have been doing so in these groups.  If you don’t know about them then check them out and join for more info.  

White Mazda 3 stance with lowering springs
Wide view of Mazda 3 with art in back

Thanks for tuning in with CorkSport.  We hope you are as excited about the 4th Gen Mazda platform as we are!

-Barett @ CS

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Barett’s 1/2 Mile Mazdaspeed 3 Build – Part 1

Hey Everyone, if you don’t know me already I’m the engineering manager at CorkSport Performance & @Halfmilespeed3.  I want to make a formal greeting and invite you to follow along as I take the next huge step with my personal build.  I drive a 2009 Mazdaspeed 3 that has been through many iterations.  I bought it nearly 6 years ago and have since used it in excess to support CorkSport R&D.  Hundreds if not thousands of passes on the dyno with so many parts…it’s been a beaten test mule.  The time has come to set a focus.

2007-2009 Mazdaspeed 3 Crashbar

Now, with the 4th engine going in it, I’m setting the build focus for ½ Mile Drag Racing.  Power, Aero, and some “Mad Scientist” R&D is going into this build.  (see WTF is THAT)

Mad Scientist Add-ons
600hp Mazdaspeed Build Path – CorkSport Barett’s 2009 Mazdaspeed

My goals are 700whp on the CST6 stock flange (with Will @ PD Tuning giving it the sauce) and 180mph in the standing ½ mile.  I plan to play in the 1320, but half mile is the focus.  My first event was going to be Never Lift @ Coalinga Munical Airport in Late March, but with recent events, this was canceled and a new date has not been set.  Fingers crossed the country gets through this and the next events hosted by Shift S3ctor Airstrip Attack in June and November hold.

Back to the build…I know that pushing a Mazdaspeed through the air at 180mph is a lofty goal and that physics are against me.  With the help and advice of Aaron O’neal @ English Racing I am exploring high-speed aero design. 

Gen 1 Mazdaspeed Parts

The primary goal is stability at high speed.  I want to be safe in this type of racing so I need to do what I can to make the car stable and predictable at speed.  This means I need the car to cut through the air as smoothly as possible, and if possible, generate downforce. 

To do this I’ve made a prototype drag wing (which I will share more detail on in a later blog) per the advice of Aaron and my research.  This wing is two feet long at the top! And with the closed sides, this should reduce the amount of lift generated at the back of the car.

There is still a lot more work to do here but you get the idea so far.

Splitter Mount
CorkSport

Upfront I am still very much in the conceptual phase of design.  Nearly the whole front bumper will be sealed off with a single sheet of ABS plastic formed to the front of the car.  The only opening will be a rectangle about the size of the intercooler for cooling airflow.  I also plan to build a chassis mounted splitter.  The red parts in the image above are the one-off brackets I designed to mount the splitter to the chassis and still be able to adjust the height (Again I’ll share more detail in future blogs as the prototype comes together).

CorkSport

The other less intuitive aero bit I’m doing on the front of the Speed is hood venting.  Thanks to Jonathan Castro @ JC Speedworks for the hood vent I’m able to kill two birds with one stone here.  If you’ve done any type of racing you know heat is a killer and must be managed.  With this hood vent, I am both evacuating any high-pressure air build up in the engine bay and promoting more efficient airflow through the intercooler and radiator. 

With the 300 miles I’ve put on the car, I can already see a huge difference in normal operating temps.  Maybe more vents are in the works? 😉 Oh and shout out to @mz_rawr (Aaron Maves) for cutting holes in my hood.

CorkSport Mazdaspeed 3 Transmission Mount Blog

In the process of getting the engine and transmission together, I wanted to fix a 2nd gear drop out issue I had.  Over a weekend @thatonepnwguy (Bryce Peterson) and I split my transmission and replaced the shift forks.  We certainly did it the wrong way and had to chase some balls around and get them back into their respective locations; despite all that, don’t be afraid to tear into things and learn the hard way. 

How To Achieve 400 WHP In Your Mazdaspeed Blog

The powerplant made it in the car and is running great.  Right now I’ve got about 300 miles on the engine.  I’ve been working out some little details with heat management and setup of the Vacuum Pump (WTF is THAT).  I am just now starting to do logs and tuning with Will Dawson at Purple Drank Tuning.  With these goals, I still intend to keep the car street legal and driven on a nearly daily basis (I wish you could see the stares I get from people).  I’m putting this out to all of you as an invite to follow along with the build on Instagram @halfmilespeed3.  All the inside info and goodies are there for you to see along with @corksport for other stories and build updates.  I’m stoked for this season and to explore a racing series that has largely been untouched by the Mazdaspeed community.  I will be finding limits and new challenges for the platform that I hope to overcome.

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CorkSport Mazdaspeed 6 Front Mount Intercooler

The MS6 FMIC installation gives you a stealth install with minor trimming and allows you to keep the windshield washer bottle.

It’s been a long time coming but it has finally returned: the CorkSport Front Mount Intercooler Kit for Mazdaspeed 6! We’ve had many challenges on this project but we’re happy to report that it’s finally here and better than ever. We originally released this way back in 2012 (check out the release blog HERE for a throwback) but the only thing we kept from that kit was the intercooler core itself. All of the piping, silicone, and mounting has been redesigned for best fitment and minimizing trimming needed for install. Check out the images and full info below!

Superior to the factory Mazdaspeed 6 TMIC, the CorkSport FMIC gives you consistent cooling all the time without heat soak

To start things off, let’s look into the intercooler itself. It is a unique design where both the inlet and outlet point toward the driver’s side of the vehicle. This means our pipe routing is a little more complicated than most, but it makes it much easier to fit as you do not need to relocate your windshield washer bottle or deal with any of the fitment issues that come with squeezing a pipe through the passenger side of the car.

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The bolt in Mazdaspeed 6 FMIC kit which makes it the best intercooler kit available.

The intercooler core is a high flowing, bar and plate design that measures 21”x10”x3”. This is good for efficient flow up to 500-550WHP yet adds minimal boost lag, even at lower power/boost levels. This big core fits snugly behind the crashbar to eliminate trimming the crashbar or your underbody shields. There is still some trimming required to fit the core and piping, however almost all of it is trimming on plastic components, with one metal cut on a thin sheet metal bracket.

Mazdaspeed 6 FMIC fits up to a 4 inch SRI

Moving onto the piping, the CS intercooler kit uses varied piping sizes for the hot and cold side intercooler pipes. The 2.25” hot side pipe ensures the charge air reaches the intercooler as fast as possible, helping reduce boost lag. The cold side uses 2.5” piping in the first half and 3” piping in the second half. Having this large volume of cool charge air directly in front of the throttle body helps with throttle response and the large diameter further helps with peak flow capacity. This piping setup has proven itself to work great on our GEN2 MS3 FMIC kit, and has been pushed to 684WHP on Barett’s GEN1 (he modified the GEN2 piping to fit his GEN1).

Wire reinforces silicone hoses make the Speed 6 FMIC a quality product

There was painstaking care taken to ensure the kit is as easy as possible to fit on your MS6. The hot pipe has a lot more freedom for intake fitments than our previous kit and we made sure all the CS intakes fit like a glove. Other aftermarket intakes have not been test fit but check out the images, they will give you a good idea if your SRI will fit or not. All the piping is mandrel bent and comes in a polished finish, so it is ready to install right out of the box and look and perform great!

Mazdaspeed 6 FMIC kit

Keeping everything together is the custom designed silicone couplers. You may notice that some of the silicone sections are longer than a typical silicone coupler. This is to ensure the best fitment as some shapes can simply not be made easily in a piece of pipe.

Front Mazdaspeed 6 with Front mount intercooler CorkSport product

As with most CS silicone components, each coupler uses 4-plys of nylon reinforcement braiding and 5 layers of silicone. This is typically very good at resisting expansion under high levels of boost; however, we wanted to really make sure the long couplers of the MS6 kit do not expand. Any coupler longer than about 6” uses an extra layer reinforcement made of metal wire. This further resists expansion under boost, and even helps keep all the piping stable between mounting locations. While the outside of the coupler may look bumpy, the insides are still very smooth like a typical piece of silicone.

A complete FMIC for the speed6, everything you need to install is included except the tools

Each Mazdaspeed 6 intercooler kit comes with everything you need for install. Stainless steel T-bolt clamps are included for each connection to ensure secure, leak free joints. The intercooler mounting bracket, hardware, and full color install instructions are also included so you know you can get the job done right.

The MS6 FMIC installation gives you a stealth install with minor trimming and allows you to keep the windshield washer bottle.

We’re happy to finally have this out and are excited to see you all get your hands on them. Be sure to drop any questions you may have below and check out the product listing for more images!

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B-Spec Racing

B-Spec Mazda 2 racing action at Indy

The following post is from a race prep shop Chris Taylor Racing Services out of Texas. Chris purchased our Mazda 2 B-Spec car we built back on 2012 and it is still out racing and winning after a decade of use on the track.

The first race of the 2020 SCCA Hoosier Super Tour was at Sebring International Raceway in Florida. It would be my first time to drive this iconic track, and to say I was excited was an understatement. As is my typical fashion, I watched a few videos on YouTube, made a few notes on what I thought would be important corners to figure out, but otherwise went wholly unprepared. Going with me would be Kent Carter in his Mazda2 that got a full front end rebuild halfway through the 2019 season after he loaned it to somebody, and Tony Roma rented my blue Ford Fiesta, while I borrowed one of my customer and friends Jon Over’s Mini Cooper.

B-Spec Racing at Sebring

Before we get to the weekend, a little back story! Jon and I drove his Mini in a fun enduro at MSR-Houston in December, and it was there driving my red Fiesta in one stint and the Mini in the other, and watching the Honda’s and Fiesta around MSR that I decided the Mini was taking an automatic rifle to a knife fight… the car was so smooth and planted that I figured going to what everybody says is the bumpiest track on earth would make up for any shortcomings the car may have. And given that I was able to chase down and pass the 2019 National Champion in the car at MSR-Houston, and it didn’t have the new header, I really thought I’d be able to shine at Sebring!

So off we go, with a little detour through Houston to pick up some Spec Racer Ford’s to deliver to Sebring… but not before the trailer frame decided to crack over the rear axle and set the trailer wall on the tires! After a 6 hour wait and an amazing mobile welder, I was back on the road, even arrived in Sebring just a few hours after load-in opened! Kent and I signed up for the Thursday test day, having never driven Sebring, while Tony did his practice on iRacing. Joining us in B-Spec for the weekend were Joe Gersch (who skipped the test day as well but did this race last year) and a newcomer to B-Spec but a local to Florida, Bob Iverson. Bob was kind enough to let us follow the first 2 practice sessions and speed up our learning process, then he handed the car over to his coach for the third session. While Terry Borcheller drove off into the sunset in Bob’s Honda Fit, I was able to run under the track record in my third session on old scrub tires!

Friday comes and our morning practice is good but the track feels dirty and slow, I run an OK time but not what I was doing the day before. The afternoon qualifying is unpleasant with all the traffic, and it seems with the Prod cars any time we try to come up with a Plan to get good laps, the old adage attributed to many but originally from Helmuth von Moltke the Elder, “No plan of operations extends with certainty beyond the first encounter with the enemy’s main strength” continues to rear its ugly head for us. I’m able to put the Mini on the pole, but not run laps like I was on Thursday. This part of the plan is still OK as I figure we’ll be able to run faster times Saturday morning with cooler temps as long as the track is clean. 

Helmuth, or Murphy, or whoever it is rears their head Saturday morning and a small downpour occurs during AM Qualifying, so not a single one of us in B-Spec goes out. Which is nice, because I still get the pole! My first EVER, much less at a Super Tour! I’ve always said I’m not a qualifier, I’m a racer… but apparently I can run a quick lap every now and then! Thankfully the race is dry, we’re doing a split start so we’ll have a few laps before we catch the backmarker Prod cars, and I’m stoked. As I’m new to the Mini I’m still learning the sweet spot in the rev range, and I was in the wrong gear and wrong RPM for the start, which makes for an exciting one. I slot in behind Bob out of T1 and plan to just push him away from the other cars so we can get a good gap and battle it out at the end. Finishing the first lap I get a hell of a run out of 17 and clear Bob into T1, but going into T7 I touch the rumbles inside and the RF axle snaps! I spend the rest of the race watching from outside the guardrail in T9 as Joe and Tony duke it out after Bob had a tire go down, with Joe ultimately getting the win! Kent rounded out the podium.

Once I confirm its an axle, the odyssey of finding one in central/western Florida begins. First a parts house just up the road says they have one. When we get there it turns out it’s not for a 1.6L, hatchback, 5 speed. Evidently Mini uses a different axle for everything, I think even different color cars have different axles! Thankfully Kent was my chauffeur and drove and helped find the proper axle at a 24 hour Autozone warehouse/parts counter near Tampa, or I’d have not raced Sunday! With the proper axle in hand we got back to the track at 11pm, and I decided then I’d just wake up early and put the axle in in the morning. 

With a new axle and a bit of apprehension, we take the green Sunday and my cousin and his son are there to cheer me on! The announcers got word of our axle adventures and talked about me at length as I drove away from the field, Bob dropping out with an engine issue after a few laps. With my first Super Tour win well in hand, I come upon a Prod car that I’m lapping for the SECOND TIME, unfortunately in a standing yellow zone (this would be the second lap we’ve passed this standing yellow), and he decides to come nearly to a complete stop before the incident. Not wanting to pass under yellow, I come to a nearly complete stop in Turn 16 too, which leads onto the back straight, and now Tony and Joe have been able to exit 16 at full tilt and overtake me. The B-Spec cars are not powerful and it takes me a lap to get my momentum back, and thankfully as we go through 17 and onto the front straight no white flag so I’ve got 2 laps to get by both of them! I follow for most of that lap and get a huge run out of 17 the next lap coming to the white flag, past Tony, and what-the-holy-hell-why-are-they-waving-the-checkered as the overall leader passes us at the line… because I guess his 15 second lead over 2nd place wasn’t enough to let us finish our race.

So it was a rough and tumble weekend, but I came away with a track record, a 2nd place, and my customers brought home 3 trophies! So while my weekend generally sucked, it was highly successful and a good way to kick off the 2020 season! 

Full race video from Sunday is above and track record lap are posted on my YouTube, check ’em out and give me a subscribe if you like hatchback / pizza delivery car content! Some cool postcards, B-Spec shirts and G-Loc Brake Pads are for sale through this and my other website, tracksideatthecircuit.com — pick up some sweet B-Spec merch today!

Ciao

Chris

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MZR DISI Single Runner Intake Manifold Gasket

Mazdaspeed 3 Thermal Barrier Intake Manifold Gasket

The CorkSport Single Runner Intake Manifold Gasket is here! Designed for OEM and upgraded intake manifolds with or without ported cylinder heads on the DISI MZR in the Mazdaspeed 3, Mazdaspeed 6, and Mazda CX-7 Turbo, the CS Intake Manifold Gasket is one of those things you don’t realize you need until it’s too late. The OEM gasket often fails to seal once reused and can cause a restriction when going to enlarged ports. This can be frustrating as who wants to take their car back apart after a manifold upgrade because of a stupid gasket? If this sounds familiar, read on as we introduce you to the CS single-runner gasket!

Mazdaspeed 3 Thermal Barrier Intake Manifold Gasket

We collaborated with Cometic gaskets to design the intake manifold gasket; testing multiple materials to really determine what will hold up to the abuse of a Mazdaspeed. Cometic’s Aluminum Foamette Material (AFM) in 0.060” thickness was by far the best choice. It uses an aluminum core surrounded by a synthetic nitrile rubber coating. This material seals fantastically well, even if there are some minor surface imperfections or even O-ring grooves that are present with some aftermarket intake manifolds. This material is also resistant to motor oil and fuels, plus can be reused should you need to perform valve cleaning or have to take your intake manifold off for an install.

The Mazdaspeed 3 intake manifold gasket fits with stock and most aftermarket intake manifolds found on the Speed 3 Speed 6 and Cx7

Aside from offering better sealing than an OEM gasket, the CS IM gasket offers performance benefits. When going for more power, it is very common to upgrade the port sizes on the intake manifold and/or cylinder head. Doing this and reusing an OEM gasket can leave an edge of a gasket or even the center dividers of the OEM gasket in the way of airflow. The CorkSport IM gasket eliminates this problem by using enlarged ports that will suit the most aggressive porting with no flow restriction. Plus, we went to a single runner opening to eliminate the divider present in the OEM gasket to further prevent flow restrictions. There is also the added safety benefit, as a piece of an OEM gasket hanging in the airflow path could break off and enter the engine which would never end well. This is truly a performance gasket, meant to give you room for whatever flow you want to put through it.

The Single runner MZR intake gasket goves the best flow without the divider obstruction in the intake runner

There is also a less obvious performance benefit than flow: thermal insulation. OEM gaskets are made out of metal, which means as your engine heats up, this heat can directly transfer easily into your intake manifold. This is also an issue with O-ring sealing as the intake manifold is directly touching the cylinder head. More heat in your intake manifold means it’s harder for your boosted air temps to stay cool when traveling through your intake manifold. While not a huge benefit, colder charge air will always help you make more power. Since the CorkSport Single Runner IM Gasket has the synthetic nitrile rubber coating, heat transfer into the intake manifold is more difficult, keeping your charge air just that little bit cooler!

The Speed6 gasket allows for plenty of space for porting if you are going to the maximum on your MZR DISI engine.

The CorkSport IM gasket comes with a spacer for the lower mount of the intake manifold made of the same AFM material. This is critical as the CS gasket is six times thicker than OEM so the lower mount no longer lines up properly. Failure to use a spacer like this can cause leaks at the cylinder head flange or worst case, warping or damage to your intake manifold or cylinder head.

Mazda MPS 3 and MPS 6 performance intake manifold gasket

The CorkSport Single Runner Intake Manifold Gasket is a great upgrade to optimize your manifold upgrade or simply ensure your next maintenance day goes smoothly. Let us know if you have any questions and visit the product listing if you’d like to pick one up!

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