Barettโ€™s 1/2 Mile Mazdaspeed 3 Build – Part 1

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

2007-2009 Mazdaspeed 3 Crashbar

Now, with the 4th engine going in it, Iโ€™m setting the build focus for ยฝ Mile Drag Racing.  Power, Aero, and some โ€œMad Scientistโ€ R&D is going into this build.  (see WTF is THAT)

Mad Scientist Add-ons
600hp Mazdaspeed Build Path โ€“ CorkSport Barettโ€™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 ยฝ 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 buildโ€ฆI 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 Oโ€™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 Iโ€™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 Iโ€™ll share more detail in future blogs as the prototype comes together).

CorkSport

The other less intuitive aero bit Iโ€™m doing on the front of the Speed is hood venting.  Thanks to Jonathan Castro @ JC Speedworks for the hood vent Iโ€™m able to kill two birds with one stone here.  If youโ€™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 Iโ€™ve put on the car, I can already see a huge difference in normal operating temps.  Maybe more vents are in the works? ๐Ÿ˜‰ 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, donโ€™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.ย  Right now Iโ€™ve got about 300 miles on the engine.ย  Iโ€™ve been working out some little details with heat management and setup of the Vacuum Pump (WTF is THAT).ย  I am just now starting to do logs and tuning with Will Dawson at Purple Drank Tuning.ย  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).ย  Iโ€™m putting this out to all of you as an invite to follow along with the build on Instagram @halfmilespeed3.ย  All the inside info and goodies are there for you to see along with @corksport for other stories and build updates.ย  Iโ€™m stoked for this season and to explore a racing series that has largely been untouched by the Mazdaspeed community.ย  I will be finding limits and new challenges for the platform that I hope to overcome.

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The First and Only Performance Mazdaspeed Throttle Body with NO Sacrifices

Mazdaspeed3 intake manifold and throttle body installed

Many have tried, but few have succeeded to retrofit or modify an existing throttle body to work with the Mazdaspeed DISI MZR platform.

As you know, CorkSport does things a little differently, and as a result, we started from the ground up to create the best performance throttle body possible with no sacrifices to drivability or reliability. Introducing the CorkSport 72mm Throttle Body for 2007-2013 Mazdaspeed 3, 2006-2007 Mazdaspeed 6, and 2007-2012 Mazda CX-7.

Starting from the ground up means 100% brand new parts, no reworked or refurbished components anywhere.  

We start with an aluminum investment cast body that is made to our specific design specifications.

A flat faced throttle plate is added to gain a little bit of extra flow by avoiding the bump of a traditional round pivot shaft.

Finally, new electronics are added that are based upon OE logic to avoid any tuning and calibration issues.

To retain easy installation, we knew we had to keep the OE bolt pattern. With this, we wanted to maximize the throttle plate diameter for maximum flow. We ended up increasing from 60mm to 72mm. This may not sound like a huge increase, but the OE Throttle Body fits inside the CorkSport Throttle Body with plenty of room! The 72mm size also fits well with both 3โ€ and 2.5โ€ intercooler piping to fit almost any TMIC or FMIC setup. Finally, we did away with the OE gasket (which is too small anyway) and replaced it with a durable O-ring that will hold up to oil, gasoline, methanol, and other fueling options that it may come in contact with.


The CorkSport Throttle Body underwent extensive testing to ensure that it will not fail during daily use and to ensure it performs as well as we expect. The throttle plate underwent endurance testing to validate the D-shaped pivot can stand the test of time. During flow bench testing, we found that the CS flows about 150CFM (~33%) better than the OE throttle body when 75% open (accelerator pedal fully depressed).

Check out the graph below for the full data.
Mazdaspeed Throttle Bdy Graph for flowbench testing

In daily driving testing, we noticed better throttle response with no CEL or choppiness. In power testing with a midsized turbo (~GT30 size) we found the throttle body caused faster spool, but when we moved to a big turbo, things got interesting. With a GT35R, the CorkSport Throttle Body caused 100-200RPM faster spooling and an increase in power. Check out the dyno graph down below to see the difference between the CS Throttle body (blue) and the OE throttle body (green).

Dyno stats for the Mazdaspeed 3 Throttle Body

Each throttle body ships with fresh stainless steel mounting hardware, a 3โ€ stainless t-bolt clamp, and your choice of silicone. We have options for FMIC, Mazdaspeed 3 TMIC (which also works for you CX-7 guys), and Mazdaspeed 6 TMIC.

Mazdaspeed Intake Manifold with Throttle Body
If youโ€™re looking to take your Mazdaspeed3, Mazdaspeed6, or CX-7 to the next level, or squeeze that last bit of power out of your big turbo build, the CorkSport Throttle Body can help you meet your goals.

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PRESS RELEASE: CorkSport Power Series Front Mount Intercooler Kit For the 2010-2013 MazdaSpeed 3

Mazdaspeed-3-FMIC

Due to the popularity of our Front Mount Intercooler (FMIC) Kit for the MazdaSpeed 6 and first generation MazdaSpeed 3, we are proud to release the kit for the 2010+ MazdaSpeed 3. This kit will bolt on with no bumper modifications needed and increase boost levels while decreasing intake temperature. The kit also takes advantage of the hood scoop by mounting the intake under the stock intercooler shroud, leaving a stock look and maximizing airflow.

Features:
The CorkSport FMIC Kit features an aluminum core intercooler (24 x 6 x 3.5 in) with custom cast end tanks. Flowing into and out of the intercooler is 2.25โ€ aluminum mandrel bent piping with bead rolled ends. These are connected via silicone couplers (your choice of black, red, or blue) and stainless steel T-bolt clamps. The kit includes everything needed for installation including our uniquely designed ram-air box. The ram-air box counts to the factory intercooler location to utilize the stock plastic cover and hood scoop to maximize airflow to the engine.

The CorkSport FMIC Kit can be ordered for use with the stock, HKS, or Greddy Blow-off Valve flanges. The kit can also be custom powdercoated to match your engine bay, or give it a totally custom look.

Testing:
Our FMIC Kit has been developed and tested specifically for the 2010+ MazdaSpeed 3. It has been tested in all types of conditions including hot and cold, rain and snow, freeway driving, and stop and go traffic. The kit decreases pressure drop by about 2.5 psi over the stock intercooler (down to 3 from 5.5 psi). The FMIC kit also offers an icrease in thermal efficiency of roughly 20% over the stock intercooler (up to 86% from 66%)*. On top of all of this, the core flows 30% more air than the stock intercooler. All of these features add up to a kit that was designed and optimized for the 2010-2011 Mazdaspeed 3.

Available Now:
The CorkSport Front Mount Intercooler Kit for the 2010+ MazdaSpeed 3 ships with all the hardware needed for installation and is available now via our website or CorkSport Customer Service (360-260-2675). Full color step by step installation instructions and telephone support are also included with your purchase.