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The Ultimate Mazda Performance Guide

A few years ago, CorkSport’s resident racecar driver – Derrick Ambrose – released a book titled The Ultimate Mazda Performance Guide.

The wildly popular book provides beginner and intermediate Mazda/Mazdaspeed owners a solid guide that outlines how, why and when to modify their ride.  Now that the platform is a little older, these second-hand models are more attainable for first-time car buyers and Mazdaspeed Owners specifically are hungry to transform their ride into a +400 WHP BEAST!

With so many new enthusiasts joining the Mazdaspeed platform, we have been flooded with inquisitive calls and see an increasing number of new owners post up questions about turbos,  High Pressure Fuel Pump Internals, axle back vs cat back vs turbo back exhausts, and what can I do to make 400 WHP or even 600 WHP?

Many of these new Mazda enthusiasts are joining CorkSport’s premier 7th Gear Membership to take advantage of the free swag package, free shipping in the lower 48 states and immense benefits from the troll free and exclusive 7th Gear Facebook Group – Where beginners can ask questions without getting clobbered!

So, whether you’re just starting out with a new to you Mazdaspeed3 or Mazdaspeed6, or you’ve hit the ground running with a new MX-5, Mazda3 or Mazda6 (turbo diesel!?). Our Mazda performance Guide will help answer some basic questions as well as set you on your path to get the most out of your ride.

Previous Interview with Derrick:

CorkSport: What made you decide to write a book about Mazda Performance and why?

Derrick: I really just wanted to give some of the new Mazda enthusiasts some of the knowledge that I have gained about Mazda’s from my involvement with them since the mid 90’s. Many people are just now buying their first Mazdaspeed and don’t really know where to begin. I wanted to help ease them into what they really need to know. It can be quite scary for some to jump into modifying or go into the forums or Facebook groups and not know anything.

CorkSport: We know all about the forums and responses to Newbs on Facebook haha.

Derrick: Exactly, the purpose of the book was to help give people a path and empower them with information that may take a lot of years or a lot of searching to find. I didn’t want it to just be about selling CorkSport parts, we actually mention, and feature, many non-CorkSport parts in the book. That being said, I’m very proud of CorkSport and what we have done to help the Mazda community.

CorkSport: So who is this book really for?

Derrick: I wrote this guide for the beginner to the intermediate Mazda enthusiast that really wants to learn more and really get the most bang for their buck. I wanted to answer some of the most common questions I’ve seen on the forums and in person about aftermarket performance and where to start. If you have changed your turbo or are cross-weighing your coil-overs, you are probably past this book in terms of technical ability. I did, however, include many sources for additional information, contacts and even a brief history of Mazda itself; which is a topic I may even write another book on for the true Mazda fanatic.

CorkSport: I see, what do you think was the most challenging thing about creating a book?

Derrick: Everything, (laughs). When you have no idea what you’re doing as an ‘author’, it takes a LOT more time than you could ever imagine. I was lucky to have a lot of help from some truly amazing people and am very grateful to all of them. Writing a book is a much bigger endeavor than I would have every thought, but having an actual piece of history afterward is truly a special moment. Having that glossy cover in my hands, seeing the ISBN on the back and knowing that I will be in the Library of Congress forever is just an amazing feeling. It’s weird how just making a book can make you feel patriotic, but it really did.

CorkSport: Well hopefully we can talk you into signing a few for us and we look forward to helping to make the next one. Thanks for letting us get a little more insight into this great addition to the Mazdaspeed community.

Derrick: Thanks, I hope everyone enjoys it as much as I did making it. If just one person gets the mod bug I did when I was younger because of this book then I will be happy.

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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

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600hp Mazdaspeed 3 Build Path – CorkSport Barett’s 2009 Mazdaspeed

If you haven’t heard already, the CorkSport Dyno Day and Summer Event was a blast with food, friends, raffles, a Show-N-Shine, and the continuous string of dyno runs.  The highlight of the dyno runs came when one of the CorkSport Engineers, Barett, put his car on the rollers.  With a few minutes of warm up and anticipation building, it was finally time to see what the “CorkSport Speed” could do. 

600+ WHP Mazdaspeed 3 on Dyno

Getting past the ecstatic crowd to see the dyno screen showed an impressive 620whp/530wtq.  Now, whether you were at the show or not, you may be wondering what Barett’s setup is to support these numbers.  It’s not a short list but is simpler than you would expect. 

In this blog, we are going to layout the WHOLE build to show you how your Mazdaspeed can make 600+whp.  

Dynograph data of Maszdaspeed 3 625 WHP

The engine was built by CorkSport in preparation for setting up the Dankai Engine Program.  It features Manley Connecting Rods and Platinum Pistons, head work very similar to the Dankai 2 Built Longblock, along with the CS BSD (balance shaft delete) and CorkSport Camshafts.  Holding the block together are L19 head studs and ARP 2000 main studs.  

To get the air in and out of the engine efficiently we have an assortment of bolt-on parts and some prototype parts because what kind of CorkSport R&D car wouldn’t have some prototype performance parts on it?  To break this down in the simplest way possible we have laid out a full build list:

600hp Mazdaspeed 3 Build List:

  • CorkSport Built Engine:
    • Manley Pistons – 0.5mm overbore @ 88mm
    • Manley H-Beam Connecting Rods
    • CS Balance Shaft Delete
    • “Dankai 2” Ported Headed: Single Runner Intake, Bowl Work, Combustion Chamber Touch Up, Exhaust Porting
    • CS Camshafts
    • Stock Valve Springs (We would recommend upgrading these and plan to do so ourselves)

Now, this isn’t the complete list, but it does lay out most of the essential parts to get your Mazdaspeed 3 over 600whp.  You might have picked out a couple “prototype” mentions in that list above…well we can share a bit on the new CorkSport Mazdaspeed Turbo.  You’ve seen the power it can make…and it still has some more left in it up top, now check it out some sexy billet and massive turbine.

Mazdaspeed 3 Turbo for making 600 WHP
Mazdaspeed 3 Turbo Turbine Closeup for 600+ WHP

Lastly, none of this power would be possible without the fuel to support it.  As you may know already, the OE direct injection fuel system taps out around 380whp on an efficient build so how do we make another 240whp?  Auxiliary fueling is the key my friends, and we recently posted a blog to help you explore Methanol Auxiliary Fueling that I invite you to read.  To stay focused on Barett’s 600+whp build we have made an auxiliary fueling build list below:

Upgrade Your Turbo with the CST4

Methanol Auxiliary Fueling 600hp Mazdaspeed Build List:

  • AEM Boost Based Pump Controller
  • Snow Performance 5 Gallon Cell Trunk Mounted w/CS Prototype Mounting Bracket
  • AEM 80 micron in-line filter pre-pump
  • ProMeth 220psi Pump (Essential for flowing this volume of methanol)
  • Snow Performance Solenoid
  • Devil’s Own 1in/4out distribution block
  • 4x Devil’s Own 90degree nozzle holders
  • 4x ProMeth Compact Check Valves (Essential for proper AFR control between shifts)
  • 4x Devil’s Own D07 Nozzles (One per intake manifold runner; each flowing ~10gph)

Despite that this auxiliary fuel setup is providing the fuel required to support just over 600whp; it is at the ragged edge of what can be supported.  Looking at the dyno graph further up you can see torque decline after 6000rpm and horsepower go flat. This is due to the auxiliary fuel system reaching its maximum fueling capacity and thus forcing us to reduce boost pressure as engine RPM goes past 6000rpm.  

At this power level, true port injection auxiliary fueling is the correct step to take.  Lucky for you guys and gals, we are currently exploring this path with our product R&D. We plan to give you guys and gals a full breakdown of our experience and how we built a full port injection auxiliary fuel system that can support over 600whp.  

AND…I forgot to mention one very critical aspect of this entire build.  Professional Tuning! This specific build was E-Tuned on the CorkSport in-house dyno by Dale Owen of Gem Tuning.  E-Tuning is a great way to set up your car with the tuner that is the best suited for your platform and vehicle build because it doesn’t require the tuner and the vehicle to be in the same place at the same time.  

Hang tight for more on the PI Auxiliary Fueling and thanks for tuning in with CorkSport Performance.

-Barett @ CS

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CorkSport Throttle Body Spacer

We are proud to introduce the CorkSport 72mm Throttle Body Spacer for Mazdaspeed 3, Mazdaspeed 6, and Mazda CX-7 Turbo.

This is a great product for those Mazdaspeed owners who want push past the limits of their OEM fuel system. We’ve carefully chosen nozzle locations, upgraded the inside diameter, and added an O-ring for quick and easy sealing. We designed the CS throttle body spacer to eliminate a lot of the headaches that come with adding extra fuel.

The area where the throttle body mounts is pretty tight on the Mazdaspeeds which leaves few options for adding methanol nozzles, especially the tall AEM ones. We realized right away that nozzle orientation was critical.

To prevent any modification, the top nozzle location sits at an angle that perfectly clears both the OEM & CorkSport Intake Manifold to provide an access port for most meth nozzle styles on the market. For more stealthy setups, there are two ports located on the bottom side of the CS spacer, one straight down and once again at an angle for easy usability without further modification.

We also considered nozzle depth when designing the CorkSport Throttle Body Spacer. Most nozzle styles will sit flush to the inside surface of the spacer. This prevents any irregular airflow around the nozzle locations without affecting the spray pattern of the nozzles.

Just like the CorkSport Performance Throttle Body, we enlarged the inner diameter of the throttle body spacer to 72mm. This is the maximum size that can be used with the OEM bolt pattern and ensures optimal best airflow. The OEM throttle body & gasket can still be used with no issues.

Each CorkSport Throttle Body Spacer is precision machined from 6061-T6 aluminum before being anodized black for a clean and durable look. An O-ring groove is added during machining to allow the spacer proper sealing to your intake manifold. Rest assured, the O-ring is safe with all fuels and even oil. Finally, the spacers are laser etched with a CorkSport logo for a subtle finishing touch. The entire package is wrapped up with hardware; including extended length throttle body mounting bolts & two NPT plugs for the nozzle/injector ports you are not using.

If you’re running out of fuel in your Speed and we can make installing a methanol system much easier, pick up a CorkSport Throttle Body Spacer.

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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