Tag: Mazda Performance Products

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CorkSport Customer Collaboration – Camber Plate Development Process

Our customers are our lifeblood. We live by this understanding each and every day and appreciate that you put your trust in CorkSport products and choose CorkSport brand parts for your Mazda performance needs. Proof? Many of you may get a sense of this from the quality of our customer interactions. Hopefully, you find our staff easy to reach, courteous, helpful, and knowledgeable.

From our transparent shipping costs and our dedicated staff and customer service, to our rewards program for our loyal customers, and customer collaboration efforts, we want to demonstrate how grateful we are for your business each and every day.

I’d like to take this post as an opportunity to expand on the customer collaboration concept. We’ve mentioned this before, but it’s worth revisiting with a fresh example.

We’ve conducted numerous focus groups with our customers. In those groups we’ve discussed how our customers want to be involved in the product development process. Overwhelmingly we’ve been told you want to see the development process. You want to see what’s in the pipeline and have a chance to give feedback on the design. Our best most recent example of our efforts to expand our customer’s role in the product development process is our soon to be released camber plates for Mazdaspeed3.

Our knowledgebase is a repository for all sorts of information. For the camber plate development process, we’ve posted several articles in our knowledgebase. Brief summaries are presented below. The interested reader can view each article for more details.

Article 1:
The idea for camber plates came from two customers, Eric & Todd, who turned in product ideas. Our staff reviewed the merits of their suggestion and decided to pursue it.

Article 2:
Our initial design concept was posted for feedback.

Article 3:
Prototype parts were made from the drawings. Ordinarily we’d make one set for testing. This time, we made several extra sets so that if Todd and Eric wanted to get involved in Beta testing, we were positioned to take advantage of the opportunity. After installation and testing in house, Todd took us up on the offer to test a set of the camber plates.

Both Todd and Eric gave us great feedback and even hit the forums and started a discussion. We learned that many people were apprehensive to cut their strut tower to allow for camber adjustment. From our experience we are comfortable cutting sheet metal on a brand new car, understandably many people are not! We returned to the drawing board with the intention to eliminate that requirement. Success!

Article 4:
The biggest problem we had to resolve at this point was spring interference when using the Mazda Genuine struts. This limits negative camber to around -1.5 degrees. We solved this problem by revising our recently released lowering springs to have a tighter wound coils up front.

In summary, we made these changes to the original design as a result of our collaboration efforts with our customers:
• Recessed design to remove the requirement to enlarge the hole in the strut tower.
• Larger strut bolts to reduce camber variation from removal and reinstallation.
• Longer strut bolts to allow for strut brace installations.
• Custom lowering springs to allow for more than -1.5 degree which is limited by the factory chassis using struts.

We expect to release the camber plates and revised lowering springs in early 2012.

Thank you to everyone for their feedback. Special thanks to Todd and Eric for their participation in the development process.

Rich-

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CorkSport Product Release! CorkSport 2007-2009 Mazdaspeed 3 Front Mount Intercooler for SRI

CorkSport is happy to announce another addition to our Front Mount Intercooler line with the release of the Front Mount Intercooler Kit for Short Ram Intake designed for the 2007-2009 Mazdaspeed 3.

Featuring a 24x6x3.5″ intercooler core, the CorkSport front mounted kit has been developed for optimal placement in the path of the inflow ambient air, allowing for maximized heat dissipation and reduced heat soak, a common problem associated with the stock top-mounted intercooler location.

The mandrel bent and TIG welded aluminum intercooler piping keep the kit light and are attached with stainless steel T-bolt clamps to ensure an airtight seal. Custom reinforced silicone connectors made from multi-layer nylon braid provide strength and a smooth internal transition for less turbulent airflow.

Extensive testing on the Front Mount Intercooler saw 1-2 psi increase in boost over the stock intercooler and an average pressure drop of 1.5-2psi across the core resulting in 85% efficiency for greatly reduced core temperatures.

“The CorkSport Front Mount Intercooler with Short Ram Intake is no exception to the quality standards and attention to detail I have come to expect from CorkSport products,” said CorkSport customer, Kyle Reid, “The immediate boost in power speaks for itself. The free-flowing intake system increased both torque and horsepower right where I needed it and the intercooler is positioned in the perfect location to allow for greater airflow and cooler boost temps which in turn gives me colder charged air. I could not be happier with the kit.”

The kit has been designed to integrate seamlessly with our popular CorkSport Power Series Short Ram Intake and can be purchased as a standalone kit to compliment your current short ram intake or can be purchased with the CorkSport Power Series Short Ram Intake for additional savings and power gains.

For more information or to purchase, https://www.corksport.com/corksport-2007-2009-mazdaspeed-3-fmic-kit-for-short-ram-intake.html

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CorkSport 2010 Mazdaspeed 3 – The Tireless Worker

CorkSport currently develops parts to support 22 Mazda models and at times one of the trickiest parts of designing parts for all of these cars is finding a car to use during the development process.

Occasionally it can be hard to source a car and find someone who is willing to let you start cutting on their brand new car, which is why it is so great to have our 2010 Mazdaspeed 3 at the shop to use for product development.

Many of you have seen pictures of the CorkSport Mazdaspeed 3 and say how great it looks, but little do you know that it’s a true workhorse.

In the past few months I have seen more parts go on and come back off of this car than I ever would have guessed. Hardly a day goes by when something is not being done to it to further development of our Mazdaspeed 3 line. In the past couple weeks alone it has had three different exhaust combinations on it and at one point even had a TMIC on it for a day while the FMIC piping was still installed but disconnected.

One of the great parts of being an engineer for CorkSport is not spending all day sitting at a desk. I’m able to get out and actually work on a car, put it on the lift, prototype parts, test fit samples, and get some actual real world testing on our new parts. This allows us to develop top of the line parts that have been thoroughly tested in real world environments on a shortened development schedule because we don’t have to develop, send parts out to identified R&D cars, wait for feedback, then tweak the design and start the process all over again. Being able to just walk out into the shop to look at something or install a prototype for testing is great. We can get immediate results so we can get the product out to you, the customer sooner.

We recently released our Front Mount Intercooler Kit for Short Ram Intake and some of you with large power aspirations had questions about the fitment of a larger intercooler. The kit we released with the 24x 6x 3.5″ does not require you to remove the crash bar and in order to accommodate a larger intercooler, removal of the crash bar is necessary. Having our shop car not too far from my desk, I was able to go out and fit a larger intercooler onto the speed 3, prototype some brackets, test and then adjust the design to accommodate the larger intercooler core in just over a month. We now have an option for those of you that want to upgrade your turbo and run a CorkSport FMIC for SRI. The new larger intercooler core is 24x 11x 3” and can support up to 700hp.

Having the car here also means we get to drive it and experience how new parts will act in the real world. We can find out how it handles in stop and go traffic, how comfortable it is on the freeway, and how it looks driving down the road. A couple days this week I was able to drive the car to and from work and I can definitely say that even with all of the performance parts installed, the car is still a great daily driver.

I must say having a car like the CorkSport 2010 Mazdaspeed 3 available to use as a development tool really helps us create the best possible product for CorkSport customers.

Andrew-

Current List of Performance and Accessory Parts on the CorkSport 2010 Mazdaspeed 3

Engine and Drivetrain
CorkSport Short Ram Intake
CorkSport FMIC for SRI Kit
CorkSport Cat Back Exhaust
CorkSport Racepipe
Corksport Motor Mount Inserts
CorkSport Lightweight Crankshaft Pulley
CorkSport Silicone Radiator Hose Set
CorkSport Aluminum Skidplate

Suspension and Wheels
CorkSport Adjustable Rear Swaybar
CorkSport Front Swaybar
CorkSport Lowering Springs
CorkSport Trunk brace set

Interior/Exterior Styling
CorkSport LED Light Kit
CorkSport Stub Antenna
CorkSport License Plate Frame
CorkSport Mud Flaps
J-Spec LED Tail Lights
AutoExe Front Bumper
Advan RZ 19×8.5 wheels
Yokohama S-drive 235/35/19 tires

In Prototype
CorkSport Shifter Base Bushings
CorkSport Front Adjustable End Links
CorkSport Oil Catch Can
CorkSport Camber Plates

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Quality Improvement through Product Redesign

CorkSport is dedicated to providing top quality, reliable products to our valued customers. To ensure that our products can keep meeting the demands of the market and adopting forward-looking design techniques, CorkSport may periodically announce product changes or cease product on obsolete models.

One such example of this is the CorkSport Mazdaspeed 3 Front Sway Bar that was released in March of this year. The bar had gone through several design iterations and had been tested on the CorkSport 2010 Mazdaspeed 3 to ensure fit, form, and function during the development phase, however once the product was released, one of our customers identified an issue, and with his help, we took steps to update the design.

Long time CorkSport customer and autocross enthusiast Steve Kritzberg was one of the first to purchase the sway bar. Upon initial installation of the bar, Steve immediately noticed the difference in handling over OEM bar, “The bar was a big improvement over the OEM bar in handling,” Steve recalled, “It kept the car flatter in the turns, as well as quicker turn in.” Unfortunately the stress that Kritzberg’s sway bar was under during autocrossing and his daily commute to and from work on the pothole and crevasse strewn roads of NYC, caused the bar to fail.

Steve immediately got in touch with CorkSport, “I got on the phone with Derrick and dropped him an email with photos.” CorkSport’s customer service manager, Kelly, then kicked into action and sent a stock bar to Steve to put in while engineering worked with him to identify the issue.

“The original design was pretty unorthodox,” said Steve, “The welds and finishes were nice, but during the CorkSport redesign process, I recommended they go with a more conventional design.”

As part of CorkSport’s design procedures, any major change that may impact form, dimension, quality, function, endurance or reliability, will be directly communicated to customers affected, so while CorkSport worked with Steve to improve the design of the bar, our customer service department reached out to each of the other purchasers to make them aware of the potential problem and CorkSport put out a public statement regarding the product issue.

“As soon as the problem was identified, CorkSport posted on the Mazdaspeed Forums and put the issue on the table,” Steve stated, “That is just good business!”

The redesign took approximately six weeks to complete. “I was contacted by Kelly and Derrick several times during the process to ensure the problem was being taken care of to my satisfaction,” said Steve, “The service was awesome. Not only did CorkSport send out a thank you gift in consideration for helping them with the redesign process, but also contacted me once the new design was completed to ask if I would be willing to test the bar.”

When asked how the new product is performing for Steve, he had this to say, “I really like it! I especially like the combo of the bar and the CorkSport Lowering Spring Set. The new bar is definitely stiffer than the first bar and the car feels more balanced.”

When asked if Steve had it to over again, would he still purchase from CorkSport, he responded with a resounding, YES. “Without a doubt! Great product and great service!”

Every product that is developed by CorkSport is handled with personal accountability and though we develop, design, and test our products thoroughly prior to release, from time-to-time, it is our dedicated customers that help us to refine and perfect our products to the uncompromising standards people have come to expect in CorkSport products.

A special thanks to Steven Kritzberg for working with us to develop a top performing Mazdaspeed 3 Front Sway Bar and for taking time out of his busy schedule to co-author this post!

Gwynne-

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Product Sneak Peek – CorkSport Fall Line-Up

I attended my first research and development meeting at CorkSport a couple weeks ago and spent the morning and well into the afternoon reviewing product submissions and discussing the viability and potential demand for each of the ideas that were submitted to us.

We reviewed over forty-five product submissions and ranked them on feasibility, development time, demand, and the value it would provide to our customers. Coming out of that meeting, I think customers will be pleased with some of the fantastic products coming to market over the next six months and though we are keeping our cards close to our chest on some of the exciting products we have in store for all you Mazda performance enthusiasts, I will divulge some the new products you can expect to see released in the coming weeks.

Lug Nuts – As early as next week, you can expect to see new CorkSport Extended Lightweight Lug Nuts added to our list of performance accessories. Thanks to the feedback from our Facebook Fans, we will be offering them in black as the overwhelming color of choice. More to come on this product soon!

Shifter Bushings – Coming up before months end will be the CorkSport Shifter Bushings. Removing unwanted play in your car’s shifter mechanism, our bushing kit will greatly improve the feel of shifting in your vehicle.

Gen 1 Mazdaspeed 3 FMIC kit for SRI – Expanding on the success of our recent Gen 2 Mazdaspeed 3 release of a FMIC kit for SRI, CorkSport will be releasing a version for Gen 1 Mazdaspeed 3 drivers by the end of the month! Like our Gen 2 version, the FMIC kit for SRI will provide solid power gains without the lag commonly seen in larger FMIC kit’s that require removal of the crash bar.

Mazdaspeed 6 Rear Sway Bar – Currently on a fall release schedule, the CorkSport Mazdaspeed 6 Rear Sway Bar will greatly improve handling by tightening up the rear suspension. The Rear Sway bar can be purchased stand alone or can be used to compliment the CorkSport Mazdaspeed 6 Front Strut Bar.

CorkSport LED Under Hood Lights – Also on the fall release schedule is a kit that will illuminate your entire engine compartment. The CorkSport LED Under Hood Lights are a low power draw kit that will attach to your battery, includes an automatic on/off switch and will cast a cool blue/white luminescence on your engine bay.

These represent just some of the products you can expect to see in CorkSport’s fall line-up. More will be introduced as the development and testing process winds-up.

Interested in submitting a product idea? Fill out a product idea form for consideration at our next development meeting, https://www.corksport.com/product-ideas.html

Gwynne-