600hp Mazdaspeed 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. 

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.  

The engine was built by CorkSport in preparation for setting up the Dankai Engine ProgramIt 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 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 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 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.

Lastly, none of this power would be possible without the fuel to support.  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:

 

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

 

Brett’s Build Part 3

Well guys, I am back with a part 3. I apologize in advance for the delayed release of the 3rd chapter, but the Mazda was out of commission for a bit getting some stuff reworked! That being said, we can now pick up where we left off in part 2!


As I started to settle into my new stake at CorkSport, I started adding on lots of new goodies. At the beginning of the new year of 2017, I got to throw on our prototype Stage II RMM and get rid of my old one for some testing and feedback. Not only did the vibes decrease substantially, it also held the powertrain better and was helping my wheel hop significantly. So while I was at it, I threw on a Lower Tie Bar to help even further, knowing I had plans in the very near future to make over 400 Whp.


It was now Feb. of 2017 and I knew I was wanting to reach my new power goal by Summer. So, I talked to my tuner, Erik with Drama Tune, and scheduled to fly him up here in March to dyno tune the car. I had every single piece needed to complete the 400+ Whp puzzle.

The last missing piece was fuel. At this point in time, I had two options, Port Injection or Methanol Injection. Given, that I only needed a little more fueling head room freed up I went with methanol for ease, and price. For those that are curious, I purchased the Snow Performance Stage 3 Kit.  

I started installing the kit at the beginning of March 2017. Since I was going to be putting bungs into the FMIC piping, I got the kit powder coated as well.  I installed one small nozzle right off the cold-pipe of the intercooler, and another large nozzle right before the throttle body. I left a couple inches to help the alcohol atomize. The total amount I was spraying between the two nozzles was approximately 1000 CC’s of 100% Meth as we were using it for Fuel.  

So, with the car ready my Tuner flew up and we got my car on the Dyno! Keep in mind my car is a stock bottom end, so I knew I was going to be playing with fire a bit. The general rule of thumb here: If you are on a stock bottom end and want to push the car in this fashion, always have a backup plan ready in case the engine gives out.

By the end of the session, I had 3 maps from Erik:

Pump Gas: 340 Whp

E85 Blend (3 Gallons): 390 Whp

Methanol Injection: 430 Whp. (e85 still in the tank for added knock resistance and cooling)

The torque was kept down as much as possible at 380 Ft-lbs @ 4700 RPM. So, the stock rods definitely were not in danger. Ultimately if the block were to give out in this situation, it would more than likely be the piston rings. The stock Piston Rings do not like high heat or harsh temp changes. So, the best thing you can do pushing 400+ hp on the stock bottom end is to allow time between pulls for everything to re-stabilize. This will ultimately increase the time you have before it ‘Splodes. Because, if we are being honest with ourselves, at that power level, its always a matter of when, not if with the stock block.

 



So, this is how my MS3 has been for the last year or so power wise. Built block will be in the future soon. But on this next part, I’ll dive into some cosmetics details that I’m sure a lot of people wants to know.

*Hint* “Hey Bro what flares are those”

-Brett@CS



CorkSport and Mazda Events

I absolutely love it when the fantastic humans at Corksport approach me to blog it up for them.  So let’s dive right in, no time to waste.

August is kind of a sad month if you look at a calendar.  No real holidays to speak of, it’s hot and miserable across the entire United States, and with the exception of Vigil of Assumption Day(whatever that is), August is kind of boring.  But, look no further than the CorkSport’s Dyno Day, Show & Shine and Drag Racing on August 25th!!! It’s almost like Christmas in August. Free stuff, raffles, food and drink but most importantly, great people.  Be sure to let them know if you are coming on their EVENT PAGE!

Oh, you forgot who I am.  Well, I put on one of the craziest meets for us Mazda junkies.  Mazda Takeover, yeah, I’m that guy that annoys you on the Facebook groups reminding you to come and have a weekend of a lifetime.  You might be wondering what that has to do with a Corksport Dyno day? I will gladly tell you.

Corksport has gotten behind Mazdaspeed Idaho’s little shindig in a big way.   You see, the good folks over at CS year after year make the trek, a pilgrimage if you will to Idaho for Takeover weekend.  It’s only right that we return the favor! As soon as CorkSport announced their dyno day event, posts from Mazdaspeed Idaho members flooded our local page with questions, ideas, plans and straight up commitment to making the trip to CS in August.

I might be a little biased about the Mazdaspeed Idaho group being the best group of people ever, and they are. The cars in Mazdaspeed Idaho may not be showpiece material, nor are they the fastest on the planet, but us members love our Mazda’s as if they were show cars or all out HP cars.  

Hell, one member sold his Gen 1 speed and within a year picked up a Gen 2 just because he loved the community more than the other community options given his other cars, so that’s saying something about not only the Mazda brand, his local Mazda community, but it says a lot about Corksport as well.  Having owned his new Mazdaspeed 3 less than a week, he was the first to commit to wanting to go with the group that forms to the  CorkSport dyno day! He is beyond excited to meet the people and see the building where his car part dreams come to fruition.

As of right now, I’m guessing Idaho will roll into Vancouver with 10-20 Mazda’s, which is a huge improvement over the 4 we took last year.  I’m really looking forward to this event, mostly because it gives the Western Washington Mazdaspeed and Nator OR communities another group to bond with.  Which is what Mazda should be about, forming and building a strong, unbreakable community that forges lifelong friendships through one shared passion.  I really hope some California members make the trip as well. It’s always refreshing to see other Mazda’s, other ideas, and other builds.

I didn’t ask my boss, I told him I won’t be available because I have race car stuff to do with my race car family.  And you all should tell your boss the exact same thing, and show up for one hell of a weekend out at Corksport.

See you @ CorkSport August 25th!

 

Keith Eggert

 

Dyno Numbers and You

We talk a lot about dyno testing and seeing improvements with CorkSport goodies but we rarely talk about what dynos are and why dyno testing should be a part of your build. While e-tuning using logs and v-dyno works great, tuning on a chassis dyno can be quicker and is a just a bit safer; since let’s be honest, 4th gear WOT pulls in your local area of “Mexico” can get a little sketchy sometimes. Keep reading on for some advantages of knowing your dyno numbers.

To start off, I wanted to share a little bit of knowledge of what a dynamometer (dyno for short) is and how they work. Dyno is a broad term for a machine that measures force, torque, or power. In the automotive world, we typically think of a chassis dyno that measures torque through the drivetrain of a vehicle, however, for high-level suspension tuning, shock dynos also exist. Now some of you may be surprised to hear that dynos measure torque, not horsepower. Torque is much easier to measure and can be easily converted to horsepower (HP equals torque times RPM divided by 5252 for those curious).

There are a couple names of dyno you have likely seen get thrown around: Dynojet, Mustang, Dynapack, and DynoTech to name some of the most common. Each measure power a little differently but for the sake of keeping things concise, each uses a known or controlled “resistance” to fight the vehicle’s torque that is being produced.

Dynojet and some Mustang dynos use a physically heavy drum while Dynapack, DynoTech, and other Mustang dynos use electricity or hydraulics to control the dyno’s “resistance”. Each type of dyno has its own set of advantages & disadvantages but the most important thing to remember is that they will read differently for the same vehicle. This means if you are getting your car tested or tuned on a dyno multiple times, be sure to use the same type, and better yet same exact dyno, to really see how your build has affected your horsepower & torque.

On to advantages of getting your car dyno tested. While most are not “make it or break it” changes, dyno testing can really take your build to the next level.

Bragging Rights: While an obvious one, dyno results make it much easier to compare your car to another since you have hard data to back you up. This is especially true if you are using the same type of dyno. On a lighter note, comparing your car to someone with a well-documented build can help you decide what your next mod will be.

Ease of Tuning: Consistent and accurate pulls can be had back to back on a dyno, without having to drive out to your “dyno road” after every small tuning change. In a properly setup environment, pulls will show only tuning changes instead of having to worry about every little variable that comes with on-road pulls. If your tuner is in town, having them live tune with your car right in front of them can turn a multi-week e-tuning process into a long afternoon. Plus, you won’t have to worry about an expensive ticket from the local boys in blue.

Monitoring Car Health: Friend has the same car, same mods yet are making much more horsepower? Dyno testing can show things like this that may indicate a big problem with your ride. Removing the “driver mod” from racing your friend light to light can help determine if there’s something more going on. In addition, having hard data on power & torque numbers can tell you when to stop pushing for one more psi, keeping your ride on the road and not in pieces.

New Mod Validation: Bought a part and want to see what it’s doing for you? A dyno before and after is a great way to validate your new mods and see what your next step should be. In addition, you may find out there are more benefits to a part than just max power gains. Maybe that newest part only gave you +2WHP at peak but shows gains of 10-15 through the middle of the rev range, or you can hold power to a higher RPM. Analyzing dyno graphs for more than just peak numbers is a powerful tool that can indicate how a part changes how a car feels.

Obviously, not everyone has access to a dyno and it is usually expensive to use a dyno for more than a few pulls, however, it is worth it and can give you some much-needed info about your ride while keeping you & your ride safe and out of legal trouble.

Looking for a dyno for your car? We are hosting the 2018 CorkSport Dyno Day in August. Dyno runs, food, a car show, and even drag racing are all on the agenda. Check out the Facebook event page for full details & don’t be shy if you don’t have a Mazda-we had a Fiat 500 Abarth on the rollers last year!

Hope to see you there!

-Daniel

New Year, New Gains

As the New Year rolls around, most people are looking for a change for the better in their lives.

At CorkSport we think one of the best changes you can make is more power for your Mazdaspeed. We have all the parts you need to liven up your Mazdaspeed3 or Mazdaspeed6 in the New Year.

Safety First

One of the first things to consider when modifying your Speed is the health of its engine. Performing maintenance is very important but it only gets you so far. When adding power, one of the first modifications on your list should be the CorkSport Max Flow Fuel Pump Internals.

These pump internals allow you to maximize your stock fuel system for optimum power capabilities and safer than OE A/R ratios. This means you can add the power you want and have peace of mind that your engine will get the fuel it needs.

Put the Power Down

Like the CS fuel pump internals, the CorkSport Stage 2 RMM for Mazdaspeed 3 will not directly increase the power levels of your car; however, it helps you put all that hard-earned power down. By decreasing the amount the engine can rotate, the Rear Motor Mount allows for reduced wheel hop and torque steer while providing faster throttle response and crisper shift feel.

Even we are surprised how much this engine mount changes how a Mazdaspeed 3 feels. Don’t worry Mazdaspeed 6 guys and gals, we have an RMM for you too.

Improving Airflow

Engines in an extremely simple sense are air pumps; so the faster you can get air in and out of the system, the better. That being said, some of the simplest and easiest power gains you can get from your Mazdaspeed are from upgrading the intake and exhaust. We have seen peak gains of 25ft-lbs and 33WHP from only the CorkSport Stage 2 Intake and a CorkSport Racepipe.

Checkout the dyno sheet below.

Power and torque levels will be further increased if you install a full CorkSport Turbo Back Exhaust instead of just the race pipe section.

The catback exhaust section has proven to gain up to 14WHP while the downpipe section alone has proven to gain up to 21WHP. In the dyno graph below, the downpipe car had a CorkSport Intake installed at the same time as the downpipe (hence the 50hp gain).

If that wasn’t enough flow for you, we also offer 3” and 3.5” intakes for even more airflow into your turbo. Keep in mind though, once you get into those you will need to use a new tune to ensure your car runs optimally. But check out the extra flow you get!

Turbo Upgrade

The CorkSport Drop-In Turbo is a fantastic upgrade to the stock K04 turbo that allows your car to make more power on an equivalent boost pressure. It will work with any mods you already had on your OE turbo as the CS turbo is truly a drop in upgrade. With supplemental tuning, fueling, and supporting parts, you can push your Speed to its limits.

The Next Level

CorkSport also manufactures parts that can take your Speed beyond the parts discussed above. A short list of the parts with the best power gains can be seen below:

    • CorkSport Camshafts: Replacement cams with extra lift to provide increased power and torque across the entire RPM range.
  • Bigger CorkSport Turbo? Yes, there is one in development. See this blog post for details.

No matter what your goals are for this year, CorkSport is here to help you achieve them. Whether you just picked up a Mazdaspeed and are unsure where to start, or have been driving one for years and want the excitement you once had back, CorkSport has a part for you.

Daniel

CorkSport Engineer