Sneak Peek at an Upcoming Transmission Motor Mount

Here is a treat for GEN3 (2014+) Mazda 3 owners!

We are in the process of designing and producing a CorkSport Transmission Motor Mount, (TMM), to reduce the excessive engine movement present from the factory. Buckle up as we go through a sneak peek at some features and go through the design process and decisions that all serve to give you a better mount in the end.


When approaching this project we sought out to improve the performance of the GEN3 Mazda 3 without sacrificing drivability or OEM fitment. Stiffer motor mounts are a great way to improve throttle response, improve shift feel, and reduce wheel hop by reducing the total amount of engine movement but they can hugely increase NVH (noise, vibration, and harshness). As such, there is a balancing act between finding an acceptable level of NVH for the performance gains you get.

In a typical front wheel drive car the engine is mounted in a transverse matter, that is, the engine is parallel to the axle centerline. So when the engine tries to turn the wheels, the force to do so tries to make the engine rotate in the opposite direction. Motor mounts resist this motion of the engine.

Initially, we wanted to change the orientation of the factory mount for the Mazda3 to use the polyurethane bushings in the most optimal way possible as the bushings function best when they are parallel to the axis of rotation. Doing so proved to be difficult as we were effectively creating a new pivot point in the system.

Going through this design, we also realized that overall size was becoming a problem as different transmissions have varying heights. Since this mount sits right above the transmission, this was a vital thing to keep in mind. So for our 2.5L manual Mazda 3, we had a good amount of room below the mount, but it needed to go on a serious diet to fit an automatic model. This meant moving to a drastically smaller bushing which likely would have increased NVH, only using the mount for manual models, or using a custom bracket for each different transmission & model. Check out down below for one of the early (and ugly) designs.

So we went back to the drawing board. We decided to move forward with a design similar to the OE design. Doing so allowed for a smaller mount, easier manufacturing, and a significantly wider applicable model range. This includes all 2014-2016 Mazda 3, all 2014-2016 Mazda 6, and 2013-2016 CX-5 (we have not confirmed the 2017+ models years yet, but there’s a good chance this will be compatible).

Even though we went to a similar design to OE do not assume it’s the same thing. The CorkSport mount has the same diameter bushing as the OE mount; however, the OE mount does not utilize all the available space. This means that in addition to the stiffer polyurethane material, there is simply more material to resist the engine’s movement.

The CorkSport TMM utilizes billet aluminum for the main body of the mount with stainless steel plates for the washers and the angled section of the mount. This provides a more attractive and lighter mount than the OE offering while retaining the same strength and fitment of OE. Check out the picture down below for a look at one of our 3D printed prototype test fits.

We just received our first functional prototypes for further fitment and testing since 3D printed plastic parts don’t support an engine & transmission very well. With these samples, we can determine exactly how stiff to make the polyurethane and finalize the best possible design for you. During our test fit, we even noticed some deterioration of the OE mount.

This OE mount came off of the CorkSport Mazda 3 racecar. While it does not have many miles, they have all been racing miles that are very hard on all vehicle components. Check out the image down below to see a comparison between the used mount (left), a new mount (center), and the CorkSport prototype TMM (right). It’s interesting that Mazda has made some changes to their OE mount in the last few years. What you can’t see very well is that the racecar’s mount has areas where the rubber is starting to separate from the metal center section of the mount. There are even a few small tears forming on some of the inner bushing surfaces.

These signs of wear are encouraging to us at CS since this means we are helping to solve a potential problem facing 2014+ Mazda3 owners. As such we could not wait to get the TMM on a car for testing. Fitment is great so far, and we were even able to overcome some minor manufacturing errors. The first test for the mount was with the CorkSport Mazda 3 racecar at the 25 hours of Thunderhill. This event is an endurance race that runs for 25 hours straight.

The Mazda3 completed 613 laps during this time covering over 1800 hard miles. This is a torture test for any part, and I’m happy to report that the CorkSport TMM passed with flying colors. The drivers liked the mount and Derrick (who owns the car) reported greatly reduced slop in the transmission when shifting. Here is what the mount looked like after the 25-hour long race:

Aside from being very dirty and having a few scratches where it was bolted down, the mount had no issues and was still in good working condition. It already has a new home in a daily driven Mazda 3 to get even more testing done. Initial impressions are good, but we will look to decrease NVH as much as possible before any of you get your hands on it. Look for the CorkSport 2014+ Mazda 3 Transmission Motor Mount in the next few months.

25 hours of Thunderhill

25 hours of 69

For many people across the USA, the days after Thanksgiving means one thing. To them, it’s the start of the Christmas season. The beginning of holiday shopping, pumpkin spice lattes, and the best home cooked meals you can’t wait to dive into.

However, for a small select few group of individuals and teams, it’s a time for something completely different. It’s a time to see what you are made of, a time to put it all out on the table. A time where you know if the past year of planning, testing, and preparation are about to reward you greatly or tear you down completely. It’s the time where you hope to be able to stand up on a Sunday at noon and can say proudly “I survived the 25.”

For those lucky few (some call them crazy or stupid) the weekend after the Thanksgiving Holiday is what you might call a different type of holiday.

For the past 15 years, the 1st weekend of December is when some of the worlds best pro and amateur drivers descend upon a small city in Northern California known as Willows. Just on the outskirts of this quaint little city lies a little well-known road course titled merely “Thunderhill.” Now what makes Thunderhill so unique, well it’s probably the fact that this venue host the longest and most extreme endurance race in all of North America. For 25 hours straight; teams, coaches, drivers, and fans endure the rain, cold, dark, lack of sleep and more to try and make a name for themselves, and this year CorkSport did just that. Made History…

 

 

While attending the 25 Hours of Thunderhill is nothing new for CorkSport as we have spent the past several years supporting Mazda North America and their racing efforts with logistics, crew, and parts. This year was the first year where we entered a new team ourselves and brought our car, crew, trailer, and everything else you need to try and survive 25 hours of racing.

Sadly MNAO did not attend this year so it was up to us to make sure that the brand and name would make a forceful showing at the event and that is precisely what we did.

 

 

To start this whole thing off, we brought out our 2016 Mazda 3 GT. You guys are more than familiar with this car as Co-owner, and founder of CS Derrick Ambrose has been piloting this ride for two race seasons now in SCCA racing. We spent several weeks leading up to the event preparing the CorkSport Mazda3 for this daunting task.

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We got extra safety equipment installed, upgraded our data acquisition package, optimized and engine tune for the  2.5L engine, and even installed some upgrade prototype pieces to have the car suited for the race.

Some of the CS goodies that were on the car during the run where our SRI, Cat-back exhaust, RMM, sway bar, and some prototype pieces like our aluminum skid tray and upgraded transmission engine mount. We needed the best parts we could get in there if we wanted to be competitive and make history.

No one has ever raced the 3rd generation Mazda 3 for this long in any endurance race. This car started off just like any other Mazda 3 and still retained a full OEM chassis, transmission, and engine. The engine internals where untouched and the transmission received a CorkSport LSD.

 

The team showed up on a brisk and cold Thursday morning, and we went to work. We immediately set up and got the drivers briefed. We got some practice in on Thursday followed with some qualifying on Friday all to be prepared to push this car to the limit for 25 hours. The team grabbed the pole position, and we were 1.5 seconds ahead of the next car which was fantastic. It showed we had the pace and ultimately the faster car. Fast forward to Saturday, and the flag drops green.

We had a great start and excellent drivers in the car. We struggled a bit through the night with consuming tires at a rate faster than we had anticipated and also had a few issues with how quickly we could get fuel into the car, despite the problems the team and the car pushed through the night. With just a brake change and tweak to the exhaust through the night, we maintained a good pace that ultimately got unwound due to the fuel issue mentioned above.
There was a Miata in our class that could get better fuel economy and tire consumption and slowly crawled there way up to lead during the night.

As the sunlight begins to break through, we are in a healthy 2nd place but a bit far off the leader, however, it does not worry us too much as we still have a shot at a win. Things were looking good till right about hour 22. One of our driver’s radio’s in and let us know he lost 2nd gear (that’s not good). None the less we keep pushing knowing we have a spare transmission should we need to swap.

 

Now at hour 23 we get another message. “I lost 4th gear” The transmission has now lost two gears, and we get a bit nervous. The car is still going and driving strong but our lap times do suffer from not being able to use all of the gears. After a quick powwow with the team, the decision is made to leave the car out on track and finish the race between 3rd and 5th gear.

With only 2.5 hours to go swapping out the transmission did not make sense as we were very secured in 2nd place. So we did just that and pushed on through, and you know what happened? We did it. While we didn’t get the P1 spot like we had wanted we did what no other SKYACTIV-G Mazda3 had done before.

We survived the 25. We proved the chassis and the platform, we pushed harder, longer, and further than absolutely anyone else has. The car was relatively unscathed, and minus the transmission, the vehicle performed excellently. All of the CorkSport parts did precisely what they needed to and outperformed all expectations.

We took the 3rd gen platform and solidified it has a competitive car and chassis that can be used and used well at all levels of motorsports.

So, what happens next?

The Mazda 3 made it back home and now lay dormant inside of HQ. We will be spending the next few weeks going through a ton of data and running through the car with a fine tooth comb.

We’ll take the transmission apart and see what her demise was. We’ll likely strip the SKYACTIV 2.5L down as well to check out what two years of racing looks like on her. The oil is already out of the car and on its way to the lab so be sure to stick around and see what we find out there.

Now one of the great things about this is what our success brings to the community. Everything we learned here can and will be applied to all of our parts and products moving forward. When we win, you guys all win. So, celebrate our accolades with us and wish us luck as we begin to prepare for the 2018 race season.

 

Do we tackle the 25 hours again next year? Do we show up with a turbocharger and more aero? And do we fight our ways to a P1 finish? You better believe I am going to try.

 

-Vincent  

The First and Only Performance Mazdaspeed Throttle Body with NO Sacrifices

The First and Only Performance Mazdaspeed Throttle Body with NO Sacrifices

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 3” and 2.5” 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 TB 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.

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).

Each throttle body ships with fresh stainless steel mounting hardware, a 3” stainless t-bolt clamp, and your choice of silicone. We have options for FMIC, MS3 TMIC (which also works for you CX-7 guys), and MS6 TMIC.

If you’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.

CorkSport Injector Puller

For the Mazdaspeed 3, Mazdaspeed 6 & CX7

After years of popular requests, we have something that we are very excited to announce! The CorkSport Injector Puller is here, and ready to assist you with your DIY, or shop needs.

With great power, comes great responsibility! And owning a Mazdaspeed may have made you aware by now of how troublesome removing a GDI injector can be. We designed this to assist you.

YOU CAN NOW SAY GOODBYE TO:
  • Twisting a seized injector until it breaks loose
  • Rigging up some method to pull or pry out the injector
  • Beat up hands
  • Beat up injectors
  • Hours of lost time

Now, I know what you are thinking: we may be late to the party. We are aware that we are not the first ones to make such a tool, however, we wanted to ensure that we made one of the highest quality that can be used time and time again. We love that you guys buy our seals, and we wanted to help ease the installation as much as possible.

With its stainless construction, Nator can truly make use of this when it gets passed around, because it won’t deteriorate with use.

As the OE seals fail, carbon starts to built up around the injector and seal and really locks that sucker in there over time. Sometimes an injector has to be sacrificed as seen above. But, It’s amazing how much easier the proper tool can make the job.

Although it may resemble a shake weight a bit, its just your normal slide hammer style tool with a custom head designed to perfeclty fit the DISI Injector.

HOW TO USE:

  1. Take off O-Rings that will be on the tip of the Injector where it goes into the Fuel Rail. Be sure to store those in a safe place.
  2. Slide the head of the tool into position as shown.
  3. You will then put tension on the tool pulling backwards.
  4. Use your other hand to slide the hammer backwards until it hits the lock nut on the back. Repeat until the stubborn injector finally breaks free.

– The CorkSport Team

Be sure to check out our full product video on YouTube and remember to subscribe!

 

Mazda’s Game Changer

Recent news has been circulating about the new Mazda and Toyota joint production plant and what will be built there.  In a few news articles, Masamichi Kogai has been quoted saying Mazda will introduce a new and different type of CUV (crossover utility vehicle).

I have been thinking about that statement about a new and different type SUV. Looking in the marketplace, you have pretty much everything out there in size, shape, and quality.  I think there is something which is getting lost in the translation of this message.

My bet is it will be something totally new for Mazda.  

Back in 2015, Mazda showed off the Koeru concept which was hinting to future models of crossover SUVs.

Looking at the current styling and the concept cars Mazda has laid out at the Tokyo Auto Show with the Mazda 3 Kai concept this year.

The front end styling has been sharpened on this concept car, but it isn’t too far outside of what Mazda is currently offering. The changed roofline at the rear points is designed to maximize cargo space, but in a good-looking package.

I will go out on a limb and guess that Mazda is probably working on a new motor to power whatever the upcoming CUV is going to be.

The most powerful motor Mazda offers right now is the 2.5 Skyactiv turbo engine, which powers the Cx-9 and soon to be offered in the Mazda 6. This motor is based on the older Skyactiv tech though, and with Masamichi saying the new vehicle will something new, my guess is that we should expect to see another tech marvel being produced.

The last thought I have on this with Mazda is this:

If they’re coming out with something new, we may see a large-sized vehicle to go up against the truck-based SUVs from other manufacturers. It is a direction Mazda has not gone before and lines up with the statements they are giving us.

Time will tell!

-Derrick