Mazda Performance | CorkSport Mazda Performance Blog

February 20, 2017December 17, 2018

10 Tips for Garage Days

Garage days have been around for as long as the practice of modifying cars. Wrenching on your projects, some good company, hot food, cold beer — what could go wrong? Hopefully nothing, but that’s typically not the case in all honesty, especially in the Mazda game. Murphy’s Law truly takes effect, and what can happen usually will happen.

Coming from the Bay Area, where I was the main go-to tech guy, I usually had two to 12 Mazdas at my house on any given weekend. (How the homeowners association didn’t get mad, I will never know.) I’ve been around the block a time or two and seen what can go wrong on garage days. I’ve seen what turns a fun day into 20 trips to the hardware store, tools everywhere, missing parts, and the typical “What did I get myself into?” feeling.

If you have a big job coming up and you’re questioning whether you can do it, some of these tips may help you get it done faster and more efficiently, and ensure you have a good time — instead of pulling your hair out.

Tip 1: Preparation

Don’t wait until garage day to check the box. Always make sure you have the right parts and hardware in advance. Now I’m sure you’re thinking, “How could some people wait that long to open their shiny new parts?” Honestly, I agree. But some people toss the boxes aside and don’t open them until the day of installation. I’ve seen people go to put on that new part and discover they’re missing something they need. Get all the hardware taken care of beforehand.

Tip 2: Tools

Be prepared for different outcomes that may happen and have all the tools that you need at hand. If you’re lacking proper tools, I’d recommend working with a buddy who has a better collection. Having nice quality tools makes all the difference.

Tip 3: Rise and shine

Start early. Nothing sucks worse than nighttime falling with the car halfway apart (especially when you have work the next day and it’s your daily driver). If you can, plan your job to go over the course of the weekend so you’re less stressed and can take your time.

Tip 4: Plan for drops

Have a quality flashlight and a pick-up magnet handy. On a garage day, it’s not a matter of if but when you drop something important. There’s nothing worse than when that dropped part falls into the abyss or someplace you can’t reach. Keep a pick-up magnet for those annoying bolts. The flashlight is good for easily spotting shiny things, and for overall lighting during the job.

Tip 5: Really read the instructions

Thoroughly read up on the installation. Read the instructions. Read the forums and talk to some friends for tips. There is usually something helpful out there you may not have known already. For specialty jobs, know your torque specs and procedures.

Tip 6: Stay stocked

Stock up on brake clean, PB blaster, WD40, carb clean, gloves, or whatever else you might need beforehand. It’s annoying to have to stop what you’re doing just to go buy an item that was forgotten. Also, if you wear them, get plenty of gloves. Your hands will thank you at the end of the day.

Tip 7: Catch a catch can

Have something around to catch fluids. Occasionally, people get deep into a job and realize they have to disconnect a line they didn’t know they’d have to. It’s always good to have some sort of catch can. Especially ones that can be sealed off so you can dispose of it easily. This goes along with our first tip, but I’m mentioning it again because some people will overlook this.

Tip 8: Organization

Organization trays are awesome. Use sticky notes for trays or zip locks you can label to keep tabs on bolts and nuts for their component parts. This makes reassembly on a big job much faster.

Tip 9: Prevent scratches

Moving blankets or big blankets are amazing for preventing any scratches while you’re leaning over the hood. Also, blankets help to hold the tools you’re currently using. You can drape them over and attach them with masking tape to keep them in place.

Tip 10: Check your work

Once you’re all done, be sure to verify all of your work before starting the car. Verify torque specs, connectors, and the rest. After you start up, quickly check for any possible leaks, listen for odd noises, etc. For example, make sure no exhaust gas is escaping from the downpipe gasket.

I hope these tips are helpful one day! Make sure to follow the CorkSport blog for more Mazda modification tips and information. And, if these tips do come in handy, tag a photo of the finished product with #CorkSport on Instagram and show us your ride.

Cheers,

Brett

February 17, 2017December 17, 2018

Winter Projects Update: Break in Procedure

Over the past couple of months, CorkSport noticed that a handful of people — including a few guys here in the Washington and Oregon area — are doing engine builds over the winter. It’s very exciting to see more people raising their power goals and pushing the limits of the platform. As I continue to follow certain engine builds, I noticed that the question of a proper break in procedure always comes up.

We can all agree that making sure the rings fully seat themselves is the most important thing in the life of the piston, but everyone has a specific way of breaking in a newly built engine. Still, you may be looking for some guidance. Here at CorkSport, thanks to Master Mechanic and Technical Advisor Vincent Melon, we use a specific break in procedure we thought we’d share.

Life comes at you fast

Four months ago, I blew a quarter-sized hole in the notorious piston three that forced my hand — it was time to get a built bottom end. I learned a lot during this build process and, most importantly, learned what a proper break in procedure looks like. I wanted to make sure to list out the steps Vincent and I took to guarantee the engine would be solid when fully broken in so that we could help folks like you who might go through the same process.

Oil tips for breaking in your engine build

In our opinion, one of the most crucial parts of the break in process is choosing the correct oil to break in your new build. For people who aren’t sure which oil to go with, here’s what we recommend you run: Driven BR30.

Vincent has done a lot of research on this specific type of break-in oil and swears by it. This oil is super reasonable per quart, and you’ll need around twenty quarts by the time the break-in procedure is all said and done.

Burning the midnight oil

Once you have the oil you need, new plugs, and the engine put back together, it’s time for the crucial first startup. When you first start the car again, you will want to rev the car throughout the rpm range for about 15–20 minutes to get your coolant system and oil hot. This first step will work out any air bubbles in your cooling system. It will also keep any extra metal bits in the engine fully suspended in really hot oil. Once you’ve kept the rpms consistent for about 20 minutes, it’s time to change the oil. The next few steps are super easy to follow:

Change the oil again at 400 miles.
Change the oil again at 800 miles.
Change the oil again at 1000 miles.

Make sure when changing your oil at these increments, you keep a close eye on what the oil looks like. If you do not see metal bits in the oil you are changing, you’re fine. If you do notice a continued amount of metal in the oil, make sure everything is running and machined properly.

During the first 2000 miles, keep your rpms above 3000 and avoid cruising at any certain speed or rpm for long periods of time. The most crucial part of this process is making sure to change gears a lot. You can get into boost, but we recommend that you give the engine about 1000 miles before you really start romping on it. Once you have reached your 2500-mile mark, you’re good to drive it any way you like, and you can go back to using whatever type oil you want.

Cheers,

Luke

February 13, 2017

Shift Knobs and Tailpipes: A Car Guy’s Valentine’s Day

While we prefer the smell of motor oil, the wafting scent of roses everywhere tells us it’s Valentine’s Day. If you’ve got a special someone, by this point you’ve bought the flowers and candy, made a dinner reservation, and detailed your Mazda, with a substantially lighter wallet telling the tale of your romance-fueled efforts. If not, what are you doing reading this blog? Get to work before before you end up demoted to the couch!

But for those who might not have a date set up, don’t worry. Your true love (your Mazda), will always be there for you. Here are a few ideas for how you can spend Valentine’s Day with your ride so you don’t end up sitting home alone handling your camshaft.

Dinner and a movie

Spending an evening in guarantees one thing: You’re not driving. And we know you — you’re happiest when you drive. So, we’re giving you a destination. Hop in your Mazda and go grab a burger or a slice. Afterward, hit the cinema and enjoy some kick-ass action. We recommend you check out “John Wick 2” and watch Keanu Reeves wreck shop on anyone and everyone that crosses him. Or, if you haven’t seen it yet, it’s time to check out “Fast and Furious” star Vin Diesel’s “xXx: The Return of Xander Cage.” If you happen to run into a cute, single lady at the theater, why not offer her a ride home?

Check out our ultimate driving playlist for music suggestions for the ride to and from the movies.

Leather play

You’re too smart to get roped into a screening of “Fifty Shades Darker” this Valentine’s Day, but that doesn’t mean you can’t enjoy a little fun with leather — by installing CorkSport’s Mazdaspeed 3 leather steering wheel.

We’ll opt for the soft, stylish feel of hand-wrapped and stitched leather on a racing-inspired grip any day. If you’re feeling bold, add a leather shift knob. Once installed, hold on tight. You’re in for a wild ride with these two.

Can’t get enough? We’ve got a leather e-brake handle, because braking safety is just as important as an agreed upon safeword.

Oil and massage

On this special day, it’s time to treat your baby to a little TLC. Dim the lights and break out the oil … then turn the lights back on so you can see what you’re doing. Give your whip an oil change and, if you really want to splurge on your Mazda, install a CorkSport SkyActiv Aluminum Oil Catch Can. If you want to be extra smooth, add a CorkSport Oil Catch Can Drain Valve Kit to your cart, so you can really be slick with the oil. Your ride and your garage will thank you. Then, bust out the loofa and the wax and give your baby the massage she deserves, rubbing her down from tail end to headlights.

These suggestions are sure to get your engine revving. Date or not, your Valentine’s Day will be an affair to remember. Treat yourself to a new part and have the night you and your Mazda deserve. Whether you spend the night modding or taking your ride to a late-night movie, tag us with #CorkSport in a photo so we can immortalize your Mazda romance on our Instagram feed.

December 9, 2016September 30, 2024

CorkSport’s Last-Minute Holiday Gift Guide

You’re busy. We get it. You’ve got a Mazda to mod, places to drive your sweet ride, a job to do, and you’ve got to carve out a little time for that special someone. Who’s got time for holiday shopping? The lines are long, the mall is packed, and the weather — and how poorly most people drive in it — isn’t helping things. If you’re like us, you probably haven’t even started shopping yet. Which is why we’re here to help.

Whether you need to get your buddy a knockout gift for your car club’s Secret Santa or your mom’s blowing up your phone looking to add items to your list, check out our suggestions. It’s the best way to make sure grandma doesn’t get you an ugly sweater, again!

CorkSport Turbocharged T-shirt

Sure your car looks good, but how do you look? Nothing undercuts the envy you’ve generated when you pull up in your dope Mazda more than a holey old shirt. Suit up with our Turbocharged T-shirt and you can look as fly as your ride. Make sure to check out the rest of our merch as well. Your modded Mazda isn’t complete without a sticker or license plate frame letting the world know you’re rocking some of the best hardware on the planet under your hood.

CorkSport Max Flow Fuel Pump Internals

Looking to optimize your stock fuel system and protect your engine? These are the parts you’re looking for! It took us over two years of research to innovate this high-pressure fuel pump for your Mazdaspeed. Always a flawless fit and incredibly high efficiency, CorkSport’s MZR DISI Max Flow Fuel Pump Internals are precision machined, then treated, coated, and machined again. Who wouldn’t want to find more horsepower under the tree this year?

Limited Edition “Fast & Furious” 1–7 Collection

We don’t really need to explain this suggestion, right? Even if you have the 1–6 box set, it’s time for an upgrade. What would Dom do? Whether you receive it or gift it, a limited edition box set of, arguably, the greatest car guy movie franchise of all time is sure to be a hit.

CorkSport Mazdaspeed MZR Bypass Valve

BPV700W

Gifting one of our newer parts is always a surefire way to deliver a great holiday treat. An awesome addition to a turbo-charged engine bay, the CorkSport Mazdaspeed MZR Bypass Valve is a smaller piece that offers the same amount of force, so it increases turbo life while putting an end to premature wear-and-tear. It’s the gift that keeps on giving: a high-performance valve that stands the test of time.

Black & Decker Corded Flexi Automotive Vacuum

Granted, it’s not the sexiest gift, but sometimes functionality is what counts. You want to keep your ride spotless and this Black & Decker car vacuum will be invaluable in that regard. Save money on trips to the car wash and keep that interior detailing tight. It’s not the size of the vacuum, it’s how you use it!

The Ultimate Mazda Performance Guide

This is the perfect stocking stuffer for a Mazda Performance maniac. Our “Ultimate Mazda Performance Guide”, written by CorkSport’s own Derrick Ambrose, is a great guide for beginner and intermediate modders, and a good resource for expert-level enthusiasts looking for a refresher course. With over 160 pages of detailed info and full-color photos, it’s the one-stop shop for ways to get the best performance out of your Mazda.

Mazdaspeed 3 Turbo Upgrade

Go big or go home this holiday season! Sure the price tag on this turbo upgrade is on the higher end, but it’s a joy to receive or give, especially if you or your special someone need a worn out or smoking turbo. And installation is a cinch. It easily bolts into your Mazdaspeed with no mechanical modifications to replace an undersized OEM turbo and supports a range of 250–450 horsepower. You’ll come in first place this holiday season if you splurge on this gift. And hell, if you don’t get it, this is as good a place as any to cash in those checks from your aunts and uncles.

ZeroEdge Full HD 1080p Car Dashboard Camera Bundle

While we don’t recommend driving as recklessly as they do in most of those Russian dashcam videos, it’s always fun to revisit your excursions with other Mazda owners. Add some new tech to your car to match all the dope hardware under the hood. If you get one, show us where you take it out for a spin on social media. We’d love to see how you’re putting those CorkSport parts to use!

CorkSport Clearance

If your wallet is feeling a little light, but you still want to secure some great gifts, make sure to peruse our clearance section. It’s the perfect place to lock down some excellent parts at low prices that can help you arrive with a sack full of gifts in your sleigh, without demolishing your bank account. Once these parts are gone, they’re gone — so don’t wait too long before looking into this holiday gift option.

Regardless of what you end up buying as a gift or receiving in your stocking this holiday season, make sure to show us your new parts using #CorkSport on social media. Nothing brings us more holiday cheer than seeing the joy new CorkSport parts bring to our customers. Happy holidays!

November 18, 2016May 28, 2024

New Product: MazdaSpeed Dual VTA Bypass Valve

Many months ago here at CorkSport we decided it was time to bring a new high performance BPV to the market. The goal was to design a BPV that was compact, durable, and performed beyond just making noise; most importantly this BPV had to feature VTA functionality that was a right balance of daily driver friendly and performance. Ladies and Gentlemen, boys and girls, I give you the new CorkSport VTA BPV.

A beautiful picture of the outside looks nice, but does not even begin to show the many features designed into this BPV. Let’s take a look inside.

mazdaspeed bypass valve cutaway idle — Figure 1: Cutaway view in idle position

Looking at the first cutaway view shown in Figure 1, you’ll immediately notice the three O-rings. Two are located on the sides of the piston and one is located at the bottom of the piston. These are important for a couple reasons: the O-rings allow the piston to actuate/slide easily when combined with a proper lubricant and provide air tight seals in all piston positions. This allows the valve to hold 50psi of pressure without leaking.

I specifically identified the VTA port because it location is critical to the BPV design and the drivability of the vehicle. In the idle position the piston sits at approximately the same position as shown above due to the vacuum pressure sourced from the intake manifold. At idle the VTA ports are closed, keeping your fuel trims in check.

Next, let’s look at the BPV in positive pressure (building boost) situation.

mazdaspeed bypass valve cutaway pressure — Figure 2: Cutaway view in positive pressure position

Immediately after applying throttle, the intake manifold begins to increase in pressure due to the turbocharger building boost. At the same time the BPV piston is forced closed as shown in Figure 2. Like the idle position, the VTA ports are closed keeping fuel trims in check. The piston also creates an airtight seal against the base flange improving boost response.

Next you shift or get off the throttle which causes a sudden pressure change in the intake manifold and the charge pipe pre-throttle body. The excessive pressure build up in the charge pipe combined with the vacuum from the intake manifold cause the piston to open as shown in Figure 3 below.

mazdaspeed bypass valve cutaway high boost — Figure 3: Cutaway view in high boost lift off position

Unlike the idle position, the piston has moved up past the VTA ports. This is due to the excessive pressure differential between the piston vacuum chamber and the charge pipe pressure. The greater this pressure differential the faster the piston will respond and vent more air to the VTA ports. Testing has shown that the VTA ports begin activating at ~15psi or greater boost pressures on a K04 Turbo equipped Mazdaspeed.

So that’s how the CorkSport VTA BPV works, but what makes it so efficient in doing so? A combination of simple and effective features all wrapped up into one design.

Response is key to a great performing BPV, plain and simple. The piston inside the BPV must respond and accelerate extremely fast in order to reduce the pressure in the charge pipe and protect the turbocharger. Attaining that response comes down to simple physics in the form of Force = Mass * Acceleration. We can directly affect the mass of the piston via design and materials, which we were able to get down to a mere 38 grams w/O-rings. We can semi-directly affect the force required to accelerate the piston which various spring rates. Therefore by reducing the weight of the piston and optimizing the force applied to the piston we were able obtain a remarkable response time.

vta bpv response — Figure 4: CorkSport VTA BPV response time during high boost throttle close situation

Looking at Figure 4, you can see two separate graphs shown. The blue graph shows the intake manifold pressure in a 0-5volt range. Boost pressure was leveling at ~23.5psi on a CorkSport turbo equipped vehicle. The red graph shows the charge pipe pressure just ahead of the throttle body approximately where the BPV is located.

During the test the car is held steady at ~6000rpm so that boost can level off for ~5sec, then the throttle is abruptly closed; this is shown in the blue graph with the sudden decay. This causes sudden vacuum in the intake manifold and increased pressure in the charge pipe pre-throttle body. The pressure delta causes the BPV piston to react and vent which is shown with the slight increase and then decay of the red graph. The response time of the BPV is time delta from the intake manifold going into vacuum and the BPV beginning to open and vent. The resulting time delta is a remarkable 50 milli-sec or 0.050sec in general terms.

The piston isn’t the only optimized part of the BPV. The piston design and the BPV cap were designed to work together. Looking at Figure 3 you can see that the hose barb fitting is integrated into the cap design and more importantly is “inside” the piston as much as possible. By reducing the volume of the vacuum/boost signal chamber in the BPV, we have reduced the total volume that must be removed from the chamber before full vacuum occurs and can begin moving the piston. You could compare this to “shot-gunning” a can of beer. The tall boy is going to take longer than your standard 12oz right? Same idea with the BPV, but we are trying to shave milli-seconds.

bpv flange adjustability — Figure 5: CorkSport BPV flange adjustability

Another awesome feature on the CorkSport VTA BPV comes in the form of installation flexibility. Not only is the BPV compact at just 2.50 inches tall, but the flange can be adjusted to a total of five positions. The center BPV in Figure 5 shows the typical position for a Mazdaspeed BPV. From there the flange can be adjusted 15 or 30 degrees clockwise or counter-clockwise to aid in installation.

Lastly, and arguably most important, the CorkSport VTA BPV flows great. Figure 6 shows a CAD flow simulation of the BPV fully open with inlet condition 23psia @ 110F and outlet condition 7 inches of H2O vacuum. Mach flow or commonly called “choke flow” is the situation when the air velocity reaches Mach 1. At this point no more airflow can be pulled through the BPV without increasing the pressure at the BPV inlet (charge pipe). In the CorkSport VTA BPV, Mach flows begins to occur at the nozzle throat shown in Figure 6. This is to be expected with the compact design and was a compromise made in the design process; however you will notice that the CAD simulation does not take into account the potential flow of the five VTA ports. These will only increase the maximum potential flow of the BPV.

To top it all off, the CorkSport VTA BPV makes an array of noises ranging from subtle whistles to loud whooshes. I invite you to check out the video found in the product listing as words just cannot give it justice.

We set out to design a high performing VTA BPV for the Mazdaspeed community that delivered with performance, style, and entertainment. We believe we delivered with a leak-proof, fast responding and glorious sound BPV. We hope you enjoy your new CorkSport VTA BPV as much as we enjoyed designing it.

-Barett