What’s in the Pipeline for the 2014+ Mazda3?

Here at CorkSport, we are always working toward the next new product. We create our catalog just like you build your cars. Since there’s so much in development, we thought we would give you all a glimpse into what’s coming for the 2014+ GEN3 Mazda 3.

2.5L SkyActiv-G Turbo Kit

Let’s start with the big one since you’ve all been asking for updates: the 2.5 Liter Skyactive Turbo Kit. We are still making steady progress and are more excited than ever for this Mazda3 Turbo. Our functional turbo kit prototypes are slowly starting to arrive, meaning we are inching closer and closer to having our Mazda3 test car on the dyno (with added turbo noises). Stay tuned folks; this is going to be a fun one!

2014-2016 Mazda 3/6/CX-5 Motor Mounts

 

We already showed you the new and improved CorkSport Rear Motor Mount, but there’s more to come with the CorkSport Transmission Motor Mount. Check out the CAD model above to see what we’re talking about. Keep tabs on the CS blog for more info on the design and function of this motor mount soon.

2014-2016 Mazda 3 Skid Tray

The CorkSport skid trays have been consistently requested for the Mazdaspeed models; so much, that we brought them back for both the Mazdaspeed3 and the Mazdaspeed6. Now we are providing the same benefits to Mazda3 owners. We just received and test fit our first prototype skidplate, and it’s looking very promising moving forward.

2014+ Mazda 3 Suspension Kit

Need some extra handling and style for your Mazda3 but don’t want the hassle of lowering springs? We have created a kit that includes the CorkSport lowering springs, adjustable shocks/struts, and camber plates all assembled with OE accessories and ready to install. No spring compressors needed, for ease of installation. Coming soon…

2014+ Mazda 3 Front Sway Bar

Reducing overall roll or “sway” can drastically change your Mazda’s handling characteristics. We should be receiving our first prototype to test fit on our Mazda3 any day now are excited to see how it complements the CorkSport rear sway bar. Oh, and the new front sway bar is 3-way adjustable just like our ND Miata sway bars!

2014-2016 Mazda 3 Steering Wheel

Last, but not least, our leather steering wheel will be making a comeback in the coming months. Featuring a similar profile to the CorkSport Mazdaspeed3 steering wheels, it is designed to increase confidence in both aggressive and daily driving while staying comfortable and stylish.

As you can see, we are staying busy with the newest generations of Mazda here at CorkSport, but that doesn’t mean it’s the only thing we are focused on.

We still have plenty of upcoming products for you Mazdaspeed guys and gals, and for some platforms you may not be expecting. Keep tabs on the CS blog, Instagram and Facebook page to make sure you don’t miss anything!

Until next time,

-Daniel @ CorkSport

The Mazda 3 Rear Motor Mount 2.0: Back & Better

We here at CorkSport are proud to announce the relaunch of the Mazda 3 Rear Motor Mount.

Yes, you read that correct, this is a re-launch. At CorkSport we push ourselves to design and develop new and interesting products every day, with that, we try new and innovative manufacturing designs and methods in an attempt to create exceptional, competitive, cost-effective products for our loyal customers.

Sometimes those new and innovative manufacturing methods end up not being as awesome as we originally expected. This is just part of the designing and learning process. Let’s get into the details.

The original, let’s call it V1, Mazda3 RMM used a new-to-us manufacturing method of applying the polyurethane to the billet aluminum body called vulcanizing. The billet aluminum body and the steel sleeves are mounted in a fixture then liquid polyurethane was poured into the assembly and cooled until the polyurethane had set to the final hardness.  This process appeared to be very promising; each part was set up identically, it was nearly impossible to have any missing parts not sent to you, and most importantly the polyurethane was adhered to the billet aluminum body and therefore could not fall out.  More on that last bit later.

We moved forward with the manufacturing method and had a few samples made with various polyurethane durometers ranging from 60A to 80A.  After various testing, we determined that 70A was the best compromise of response and NVH (Noise, Vibration, Harshness) experienced by the driver. We continued testing for a few months to verify long-term durability and found no issues.  Hooray! We moved forward with production to get this new great Mazda6 RMM out the door to you.

Unfortunately, it appears that our testing period just wasn’t quite long enough.  Eventually, the polyurethane would fail but fail in a style we had never experienced before.  Long story short, polyurethane has excellent compression strength compared to the tensile strength.  The polyurethane was being pulled/split apart due to the forces of the engine.  

Now we had a few options of how to redesign the Mazda 6 Rear Motor Mount after going through the failure analysis.  

  • We could have simply stuck with the same design and just increased the stiffness of the polyurethane.  Increasing the durometer rating of the poly increases the tensile strength, but this would have resulted in an unsatisfactory driving experience for you which was unacceptable.  
  • The other option was to start from scratch again to create a new design that did not compromise the driving experience or the durability; with challenge comes innovation.

Again we went through many different designs, with the greatest challenge coming in the form of retaining the polyurethane pucks.  Typically the polyurethane pucks are retained by whatever the mount is bolting to, but with the Mazda motor mount, the steel sleeves extend far past the outer edge of the polyurethane pucks.  This leaves the pucks free to slide out of the billet aluminum body and cause a major failure.  

Using the conventional polyurethane puck style, we developed a design that would work, but more than doubled the number of parts needed which increased the chance for something to go wrong and drives up the cost.  This design is shown below:

 

The red arrows show the direction the conventional polyurethane puck would slide out of the body.  The red circles show the puck retention system to hold the washer and pucks in the body.  This retention design required many parts to be successful.

With the cost going through the roof we had to go back to the drawing board. There had to be a better way… and there was.  

The third major iteration shown above solved the problems of the V2 design and got us away from the vulcanized polyurethane of the V1 design.  Things were looking good.  With the V3 design, the polyurethane pucks are pressed into the billet aluminum body.  The pucks have ribs, shown with the red circles that are just large enough to keep the puck in place, but small enough to let the puck be pressed into the body.  

With this, we were able to make some clever designs to the RMM to keep it centered in the engine and chassis brackets on the vehicle.  The smaller diameter puck extends out to the ends of the steel sleeves; this keeps the entire rear motor mount centered.  The large diameter puck retains itself in the body and allows the associated steel sleeve free to slide for easy installation; shown with the red arrows.

Now… does it work? YES! Pretty fantastically, we might add!  

We have had this design on a handful of vehicles, one of those being the CorkSport Mazda 3 Racecar during the SCCA Run-Offs at Indianapolis Speedway.  Other than some dirt and grime, the tested RMM looks great.  

You were probably expecting this blog to be all about the details and reasons you should buy this performance RMM for your Mazda 3, Mazda 6, or CX-5.  All those details can be found on our website, and I invite you to check them out.

What we really want to get across here is this:

First and foremost, we will always do the best we can to take care of you and your car if there is ever an issue or concern with your CorkSport part.  

Second, if you are a driving enthusiast, if you go driving for the sake of just driving, then you need this RMM in your life. It will completely change and improve your driving experience, plain and simple.  

-Barett, CS Engineering

 

Introducing: The CorkSport Performance Polyurethane Exhaust Hanger Kit

The exhaust system on your Mazda is a loved and cherished part of your car’s character and performance.

It emits glorious sounds that keep you entertained and smiling from ear-to-ear, but if you can believe it, is only attached to your Mazda by a few soft rubber hangers.

Yes, your hard earned stainless steel exhaust is ONLY suspended by small pieces of rubber…

Here at CorkSport, we think it’s time that you show your exhaust system some love… it’s time to take the rubber off.

We present to you: the CorkSport Performance Polyurethane Exhaust Hanger kit.

This kit replaces the four rubber exhaust hangers that would otherwise be used to mount and suspend your CorkSport Performance Exhaust System; the two rear hangers on the axleback section and the two mid-pipe hangers.

But why is polyurethane better?

Well there’s a few reasons:

  • First, polyurethane is more durable and heat resistant than rubber so the hangers will perform better for a much longer period of time.
  • Second, and most important, the polyurethane used in the CorkSport Performance Kit uses a stiffer compound compared to the OE. The polyurethane hangers have 75A durometer stiffness vs the OE rubber at as low as 50A durometer. The increased stiffness helps minimize the movement of the exhaust while still providing the necessary flex between the car chassis and the exhaust system.

All-together, this means your performance exhaust system for you Mazda 3, Mazda 6, or Mazda CX-5 will not be able to move around under the car during spirited driving such as back roads, auto-crossing, or whatever motorsport event you prefer.

Keeping your exhaust system in places reduces your chance of damaging your beloved Mazda or the exhaust; it’s a win/win.

-Barett @ CS

PS: In addition to these hangers, we also carry the following other exhaust hanger options:

Dear Car Clubs: We Want To Hear From You!

Dear Car Guy,

Did you know there are LOTS of Car Guys and Gals out there in the Mazdaspeed world?

From Nator Clubs and Mazda Nova Clubs to Mazdaspeed and Meet Up Clubs, the branding is slightly different for each area and each group, but the heart and soul of the people who get involved stays the same.

Great people, big appetites (for speed and food), awesome tastes in beers and booze, and a genuine care for their fellow club members. I have made sure to attend meets and get to know the nitty gritty center of our Mazda Community, mostly because who doesn’t want to do Car stuff with their Car friends. However, I also do it because it’s an integral part of CorkSport’s vision, to give unprecedented levels of customer support and connection to the Mazda Community.

We ultimately just want to LOVE OUR CUSTOMERS, and I’ll take one for the team and meet you Guys and Gals face to face.

We’ve been to the MidWest Nator meet, the East Coast Nator Meet, and the Boise Mazda Take-over event this past year. We have also hosted our CorkSport Dyno day and given the west coast Mazda community a place to gather as well! Let me just say, it’s been amazing getting to know everyone, and seeing some awesome familiar faces.

The one thing that really stands out for me is the sense of community that is built at the center of all of this. I’ll admit I’m a people person, so of course YOU are my favorite part of working for CorkSport, however, it’s a community like no other, regardless of the title it goes by. The values of the Mazda community stay fairly similar, with mods, install days, track days, meet ups, and expansion of the love we all share for the Mazda Platform.

A group of awesome individuals, getting together, teaching those who don’t know how, and taking are of those who do (and still break down).

There are Groups all over the US (and I’m sure international), that we don’t even know about. It’s my hope that when you read this, you pass me your group pages, club names, social addresses, etc., so that CorkSport can help others in your area connect!

Near and Far, no matter where you are, let CorkSport hear from you!

Until next time, stay safe, stay fast, stay happy my friends!

-Kim @ CorkSport

 

 

CorkSport Power Series Catback Exhaust

Mazda Catback Exhaust Installed

The Mazda 6 guys and gals have waited long enough! CorkSport is proud to announce the Power Series Cat-back Exhaust for 2014+ Mazda 6 models.

Mazda 6 Catback Exhaust Muffler

There are two types of Mazda 6 owners in the community: a person with a CorkSport Axle-back and the person that sadly still has the OE exhaust. Well sit back, grab a beer, and I’ll explain why that needs to change!

First, the cat-back exhaust sounds great! Watch the video below and compare the axle-back and cat-back exhausts. While they both sound awesome, you can tell the cat-back brings a whole new level of greatness. It’s not especially louder than the axle-back, but it provides a deeper rumble to the exhaust note throughout the RPM range. Best of all there isn’t a significant increase in cabin drone, so you can still enjoy your long cruises to the beach with friends.

Second, the cat-back exhaust looks great! Starting from the exhaust manifold, you have a thick, laser-cut flange that bolts right to the OE exhaust manifold. Following that is the machined O2 sensor bung that is precision-TIG welded. Next up are some multi-point hangers to get your exhaust in place with a large packing-filled resonator that helps manage the cabin drone we talked about earlier. Continue along those gorgeous lines of the Mazda 6, and you find yourself at the axle-back section. Here you will find two packing-filled resonators and two double-wall tips that only extenuate the curves of the Mazda 6.

Now that I have your attention, let’s talk about the most exciting aspect of the CorkSport Power Series Cat-back Exhaust. It makes power! That’s right ladies and gentlemen: More power could be yours if you improve your exhaust style and sound.

For an otherwise 100 percent stock car with no additional tuning, the improvements are impressive. I think the real turning point is the unsightly squashed section of the mid-pipe. Check it out below.

Mazda 6 OEM stock exhaust

Yeah, that looks awful. Now let’s see the numbers. Check out this dynograph to see some other impressive curves. The Mazda 6 performs a whole lot better with the addition of the cat-back.

Mazda 6 Performance Dynograph

If that doesn’t convince you that the change is worth it, nothing will! Although, have I mentioned that the CorkSport Power Series Cat-back Exhaust is manufactured and CNC-formed from 60.5mm T-304 stainless steel pipe? It’ll look great for years to come.

Ready to install your Mazda 6 Cat-back Exhaust? Once you do, share a video or photo with us on our Facebook or Twitter pages. Have fun out there!

-Barett @ CS