CorkSport BIG Turbo

Good day boosted enthusiast!

We wanted to take some time to give you all a quick update on one of the many projects we have brewing up here at CorkSport Headquarters.

The project I’m referencing, in general, is our 2nd turbocharger upgrade for the Mazdaspeed 3, Mazdaspeed 6 and CX-7. This unit is a substantial upgrade over our current 18G turbocharger. This Turbo will cater to those looking to take their performance and power goals to a higher level.

Not only will it be capable of putting you well into the 465whp range but this CorkSport Turbo upgrade will be able to do it without giving up on reliability and throttle response.  

It will be very beneficial to those who have mildly-built blocks and a supporting fuel system that will allow them to get higher in the HP range.

So, let’s talk about some of the features you can expect on the upgrade and why we decided to utilize them.

 

 

Let’s start at the heart of the Turbocharger.

The new CorkSport turbo will take full use of a GTX3076R center housing and rotating assembly (CHRA). The unit is equipped with a fully sealed ball bearing cartridge, which is a nice upgrade when compared to a standard journal bearing unit. We chose to go with a ball bearing unit for a few reasons.

  1. The enclosed design of a ball bearing system allows us to eliminate the need for a thrust bearing, which can account for about 40% of the bearing system drag on the turbos rotor assembly.
  2. Ball bearings reduce the viscous drag, which allows a ball bearing unit the ability to spool up about 15% faster than its journal bearing equivalent.

The next thing you will notice on the new Mazdaspeed Turbocharger upgrade is the holes that are drilled into the compressor cover. These little holes are known as anti-surge ports and are intended to expand the turbochargers compressor map. The ports function to move the surge line further left on the compressor map which gives the Mazdaspeed turbo some more headroom before it falls out of its efficiency island. Anti-surge ports are becoming increasingly more popular in modern performance turbochargers and with great reason. They offer some unique benefits as mentioned and will be fully integrated into our unit.

 

Last but not least, as with our CorkSport Turbo, this bigger Mazdaspeed Turbo will once-again be a true drop-in unit; minus the 4” compressor inlet.

There will be no cutting, modifying, sourcing oil and coolant lines, running to the store to buy couplers, etc. This unit will come with everything you need to have a trouble-free install. As with the current CorkSport 18G turbocharger, the new Garrett-based design will come with all studs, gaskets, washers, and knowledge that you need to have a nice weekend install.

So keep your eyes peeled as we get closer to delivering more performance for the Mazda community!

– The CorkSport Team

 

SOURCES: Miller, Jay K. Turbo: Real World High-Performance Turbocharger Systems. CarTech, 2008.

 

Product Release! CorkSport Mazda CX-7 Airbox

We know CX-7 owners do not get a lot of attention from Mazda aftermarket performance companies and can often times be overlooked when it comes to performance parts that would otherwise be considered a standard offering for DISI engine Mazda vehicles.

With that said, CorkSport is happy to provide a little love for the CX-7 family with the release of the all new CorkSport Mazda CX-7 Air Box.

Designed specifically for the Mazda CX7, the CorkSport CX-7 Air Box for CorkSport SRI provides protection from the hot underhood air of the engine bay while adding additional access to ambient air temperatures, resulting in greatly reduced temperatures in and around your SRI for less heat soak and more power.

The CorkSport Mazda CX7 Cold Air Box for CorkSport SRI connects to the air induction scoop and can be further modified with an additional opening that can be connected to piping leading to the fenderwell.

The CX-7 Air Box is easy to install allowing customers to quickly upgrade their SRI and get the added advantage that comes with a CAI without the pressure drops inherent to longer intake piping.

For more information or to purchase today, please visit our online catalog at www.corksport.com

When Products in Development Don’t Make the Grade

Things don’t always go as planned. We begin a project thinking our customers will be able to get good results out of a new performance product only to find, when we start testing, those results don’t show up.

An example of this is the CorkSport Cold Pipe. After investing months in the development process, we are choosing to abandon the product and put our development efforts elsewhere. Focus on products that will provide our customers with the type of performance benefits that inevitably did not show up during the testing of this product.

How it all began:

After seeing the great success of our Top Mount Intercooler and the amazing benefits it offered, we wanted to find a way to give customers who chose to stick to a TMIC even more performance. Looking over the TMIC system we noticed that when the air exits the intercooler it immediately hits a wall. It exits the intercooler towards the front of the car, but just after exiting it is forced to the driver side.

Once we identified this potential air flow restriction, we decided that it would be worth it to try and expand the stock cold-pipe to provide a better path for the air to flow, as well as a larger volume to accommodate the increased flow seen with a CorkSport TMIC.

The development process:

We scanned the stock pipe into a solid model so we could improve flow and still provide a great OEM fit.

Once we had a CAD model, we noticed the access to one of the four TMIC mounting holes became covered so we added an access hole to be able to tighten down this bolt as well as provide a NPT fitting to be used with water/methanol injection.

We proceeded with some virtual testing and discovered that the flow was more even and fluid as it moved through the redesigned pipe when compared to the stock pipe. Once we felt good about the revised drawing, we took the CAD model and did a 3D print to check fitment and conduct real world flow testing.

The part fit great and looked great. We were very happy with how the project was turning out, so the next step was to do some flow tests to determine the exact gains that the redesigned part offered.

The outcome:

We were disappointed with the results. The redesigned cold-pipe by itself offered a 15% increase in flow over the stock cold-pipe. When combined with a CorkSport TMIC however, both pipes flowed the same. Since the intercooler’s max flow (still significantly higher than the stock TMIC) was less than either of the cold pipes by themselves, the redesigned cold-pipe and CorkSport TMIC only flowed 0.7 CFM more than the stock cold-pipe and CorkSport TMIC, a negligible amount.

Knowing this, we now had a big problem. Why would anyone want to upgrade this part for a negligible performance improvement? Sure the option to do methanol injection would be great for some but we didn’t think most people would be interested, even at our target of $125.

We hit the forums, Mazdaspeed Forums to be exact, and asked what they thought of the product and if they would still be interested in the product with the minimal gains seen. The general consensus was that although it was a great idea and seemed to have a lot of development and engineering behind it, they didn’t feel like it would be worth the cost or that we would see enough sales to warrant producing the part.

With this feedback, we decided to abandon the project and cut our losses on the development time and money we put into the product. Unfortunately this happens occasionally. We work on a project only to end up killing it before we reach production. It’s just the way development goes sometimes, but each and every time we can take it as a learning experience to further our knowledge about what projects may or may not be worth pursuing in the future.

We want you to feel confident that our products do what we say they will do and though it’s not an easy decision to scrap a product after investing thousands of dollars on development, when the alternative is to release a product that has no performance benefit when our customers are expecting one, the choice is simple, abondon ship.

Andrew-

CorkSport Announces Release of New CorkSport Stub Antenna

CorkSport would like to announce the release of the newest addition to the CorkSport line of accessory parts, the CorkSport Mazda and Mazdaspeed Stub Antenna made for 2007+ Mazdaspeed & Mazda 3, 2007+ CX-7, 2011+ Mazda 2 , 2003-2008 Mazda 6, and 2006+ Mazda 5.

CorkSport Stub Antenna

An easy upgrade to boost the look of your Mazda, CorkSport’s new shorter antenna is 2.75″ in length and will replace the oversized factory antenna. Tested to ensure they perform similarly to the OEM antenna, CorkSport antennas are anodized and made out of billet aluminum which has a long lasting, durable, black finish. CorkSport antennas come with two different size fitting studs for straightforward installation of the product that will easily attach to the Mazda Genuine antenna base.

“This product represents the beginning of what will be a string of products designed to address the glaring need for additional options in the Mazda performance accessory market,” said Rich Harris, President of CorkSport Performance. “Our ability to listen and respond to the needs of our customer base combined with our efficient manufacturing expertise has resulted in the rapid development of these products to meet the demands of our customers.”

The newest addition to the CorkSport line of accessory parts will be priced at $32, making it an easy and inexpensive way to boost the look of your Mazda. Installation for this part takes mere minutes. Simply twist off the existing pieces and install the new ones to add a custom look to your Mazda.

For more information or to purchase the CorkSport Stub Antenna, Please click here to be redirected to our catalog.