Tag: MazdaSpeed 3

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You Asked, We Answered: Our 2nd CorkSport and Mazda Q&A

Corksport Q&A

In January, we wrote a post answering questions our fans asked. It went over so well we wanted to do it again. Here are the top 7 questions we found on Facebook, Instagram, and Twitter:

Question: Would you guys consider making a turbo kit for the SkyActiv engines? What challenges would you face with that engine compared to the MZR engine?Screen Shot 2015-01-21 at 12.34.32 PM

  • Questioner: Michel Balk
  • Answer: There are a few key factors that would prove difficult to overcome when turbocharging a Skyactiv-G engine. First is the extremely high compression ratio of 13-14:1. High compression ratios and boost don’t mix well, and the supporting engine design to run that high of a compression ratio is very sensitive to major engine changes. For example: The exhaust manifold is a very well-engineered 4-2-1 design that is critical to running a high compression ratio on 87 octane fuel without pre-detonation. A typical turbo kit would replace the exhaust manifold which could cause many unknown issues. Second comes down to the overall design of the engine. Mazda has made it very clear they are chasing fuel economy, not white knuckle power. So, looking at that goal from a business standpoint, why would Mazda design the engine to handle 250+hp? That would only cost them more money. The engines are lightweight in every aspect: bearing size, connecting rods, pistons, crank…the list goes on. The SkyActiv-G engines are not built for power. Lastly, what good is a turbo kit if you can’t tune it correctly? As of right now there is not an effective method to tune the SkyActiv-powered vehicle. It’s unfortunate, but a turbo SkyActiv-G is a long shot.

Question: Give us all the info about the new CS turbo in production!

  • Questioner: Jeromy Williams
  • Answer: Well I can’t go and spill the beans, but I can give you a few tidbits of information. The goal of this turbocharger is not huge power numbers. Actually I would be in shock if anyone could get this to push 400whp with meth. The goal is to provide a turbocharger that cost only slightly more than a new K04 Turbo and is 100% bolt on. When I say bolt-on, I don’t mean “bolt-on” like BNR and ATP define it. This turbocharger requires no modifications to your current intake and exhaust systems; and no modifications need to be made to the oil and coolant lines. It’s like swapping in a new K04, but with much more power potential and no blue smoke. This effectively makes the turbocharger cheaper for the customer because none of the supporting sub-systems need to be upgraded or modified. As for some specs: Power is comparable to a BNR S3, and full spool is in the 3000-3200RPM range—depending on vehicle components. The current tune on my car is reaching 21PSI at 3200RPM with the CS EBCS running in bleed setup, and that’s on the prototype turbo without the billet compressor wheel.
Source: Autoblog
Source: Autoblog

Question: Will you be doing more products for Miata?

  • Questioner: Steve Linnehan
  • Answer: We are very excited about the new MX-5 Miata hitting our shores in the near future. The CorkSport sales manager is going to buy one as soon as possible. We plan to produce a respectable lineup of performance products for the new MX-5 Miata. From suspension to power, we will help you put some more pep in the Miata’s step, so stay tuned!


Mazda 3 Exhaust SystemQuestion: What do I need to put more HP on my 2012 Mazda 3 2.0i SkyActiv?

  • Questioner: Brayam Calo
  • Answer: CorkSport has a couple options for your dilemma, Brayam. Combining our SRI, Cold Air Box, and Power Series Catback Exhaust System showed impressive gains for the little 2.0. On our dyno, the stock 2.0 made 118hp/110lbft, but when we added the components above, we saw power increase to 135hp/123lbft. This is a respectable increase in power for a naturally aspirated engine.

Question: What is an approximated max horsepower output that can be produced in an MS3 without upgrading turbo back?

  • Questioner: Christopher DeCaro
  • Answer: This is a difficult question to answer accurately as there are so many factors that play into the maximum power of an engine. The OEM downpipe is extremely restrictive on the MS3 and is commonly recommended as one of the first upgrades. Our dyno testing showed a 50hp increase over stock with only a Stage 2 intake, downpipe and racepipe installed. So as you add more components and eventually go with a larger turbocharger, the loss in power from the OEM downpipe will only increase.

Question: Is there a way to have the engine RPM drop faster while shifting or revving from an idle?

  • Questioner: Matt Zoomin Brown
  • Answer: The rate at which an engine can rev up or down comes down to simple physics: “Force = Mass x Acceleration”. You often hear of people upgrading their flywheel from the OEM steel piece to a lightweight steel or aluminum/steel two-piece flywheel. By reducing the weight of the flywheel and the rest of the rotating mass of the engine, you effectively reduce the amount of energy needed to make the engine rev up. The opposite works for revving down. The greater the mass of the rotating assembly, the more resistance need to stop the rotation—or the longer it takes to spin down. This is a result of the “Moment of Inertia” of the rotating mass.

Question: I would like to turbo my 2010 2.5 N/A Mazda 3, what do I need to know?

  • Questioner: Cynthia Senger
  • Mazdaspeed 3 is the better turbo choiceAnswer: Like everyone else I’m going to recommend you sell your car and buy a car that was turbocharged from the factory, but for the sake of argument and fueling the fire I can point you in the right direction. The 2.5 N/A engine and the 2.3 turbo engine are very similar in design. I would start with buying a blown turbo engine, removing the exterior components, and then modifying them to work on your engine. Now the easy part is done… Next, you will need some way to tune the vehicle because turbocharging an engine that was not designed to be turbocharged is not a simple bolt-on affair. If you get past these two major hurdles, then bravo! Unfortunately, unless you improved the engine internals to handle this power, the engine will probably not live long with the added stress of its newfound power. Back to the first option: Buying a Mazdaspeed 3 makes a lot more sense in many aspects. Reliability, durability, and aftermarket support make big power much easier to achieve. Granted, a Mazdaspeed 3 may be more expensive to buy upfront, but I am almost certain it will be cheaper in the long run and will come with far fewer headaches and days without a car. I wish you the best of luck!

Thank you for your questions and keep them coming. We’ll have a Q&A every month for your Mazda performance questions.

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Barett Strecker-01

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The New CorkSport Mazdaspeed Electronic Boost Control Solenoid (EBCS)

Fighting boost spikes with the Mazdaspeed K04 Turbo or maybe boost creep with an internally gated GT3076R? Or have you gone all out with an externally gated setup? Whatever the reason, you have probably realized that the OEM boost control solenoid is not up to par and desperately needs something that is reliable and tunable.

Introducing, the CorkSport Mazdaspeed Electronic Boost Control Solenoid (EBCS), the fastest responding, highest flowing, plug-and-play EBCS available today for the Mazdaspeed platform.

Electronic Boost Control Solenoid

The CorkSport EBCS utilizes the latest technology in solenoid-controlled air valves, as well as using a light weight, low friction, and balanced valve design. The CorkSport EBCS will handle pressures from vacuum to 120psi with an operating frequency of 0 – 1000Hz and response time of 700µs.

So what does this actually mean to you?

You can build boost faster, reduce or eliminate boost spikes, and hold boost more accurately throughout the RPM range. Don’t believe me? Then check out the graph below comparing the OEM EBCS to the CorkSport EBCS both in bleed setup.

Boost Difference in the CorkSport EBCS

You can see a noticeable difference between the two graphs. Boost rises sooner, and there is no overshoot with the CorkSport EBCS. With the same Stage 2 tune, only changing the EBCS and adjusting the waste gate duty cycles, we saw an increase of 18 ft-lb of torque at peak due to the more boost at a lower RPM.

Fit of the CorkSport EBCS

Not only does the CorkSport EBCS work great, but it also fits great! Designed with ease of installation in mind, the EBCS can be located in the OEM location, or on the valve cover for turbochargers without the OEM tab. This goes for both TMIC and FMIC setups. There is also no wire cutting or soldering needed! Simply plug the electrical connector into the wiring harness and you are ready to go!

Whether you are just stepping into the Mazdaspeed world or are the horsepower king at the local dyno, there is a place under your hood for the CorkSport EBCS. This will benefit you from K04 turbocharger to an externally gated GT3582R, and there are two ways to look at the CorkSport EBCS. First, it’s a potential power adder due to its far superior response time, efficiency, and accuracy; or second, it’s a safety device for the exact same reasons. Now there is one catch…correct use of the CorkSport EBCS will require adjustments of the waste gate duty cycles. We recommend you contact a professional tuner to setup your new CorkSport EBCS.

Reasons to Buy the EBCS

Take control of your boost with the CorkSport Mazdaspeed Electronic Boost Control Solenoid! For more technical information check out our white paper write-up of the EBCS.

-Barett, CS Engineering

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The New CorkSport Adjustable Short Shifter

The Mazdaspeed platform is a pretty well-supported car in the engine performance and suspension market, but it seems to be lacking in some of the markets that truly allow you, as the driver, to connect to the car. This is especially true for the GenWon owners. Well, CorkSport has decided to help the forgotten GenWon owners become more intimately connected to their Speed3. So what are the components of a car that the driver is most intimate with? I would have to say the pedals, seat, steering wheel, and, of course, the shifter.

So which of those did we release? It’s not pedals. (Autozone has that covered.) Unfortunately, it’s not a seat, but that would be awesome. It’s not a steering wheel…yet. (Oops. Did I say that out loud?) I’m happy to say it’s a short shifter, and not the kind that goes under the hood. Sure, there are a few options out there, but they leave a lot on the table and the price seems ridiculous.

Introducing, the all-new CorkSport Adjustable Short Shifter for the 2007-2009 Mazdaspeed 3.

The New Mazda Short Shifter Is Here

Manufactured from high-grade 6061-T6 aluminum, this precision machined double adjustable short shifter is sure to give you that intimate connection and control with your Speed3. Plus, it’s 100% designed and manufactured right here in the Pacific NW, USA.

So what sets the CorkSport Short Shifter apart from the competition? This short shifter is double-adjustable, but not in the way the competition defines it. First, there are four throw positions ranging from OEM throw distance to the 35% shorter throw distance. Second, the shift knob height is adjustable from 11.75 to 9.5 inches tall with the OEM height being 11.125 inches. Lastly, just look at it: It’s gorgeous. It’s a shame it gets hidden under the shift boot.

Take a look at the comparison images below:

This image shows the forward, neutral, and back positions of the OEM shifter.
This image shows the forward, neutral, and back positions of the OEM shifter.
This image shows the forward, neutral, and back positions of the CorkSport Short Shifter in its shortest height and shortest throws position.
This image shows the forward, neutral, and back positions of the CorkSport Short Shifter in its shortest height and shortest throws position.

Of course, a product like this doesn’t come to life overnight. There were many hours of design, testing, and revision done to verify that the product you receive is the best it can be. Below are a couple images of 3D-printed prototype we made on our 3D printer to help speed up the R&D.

Mazdaspeed3 adjustable short shifter prototype

In addition to the prototype testing, we also perform FEA (Finite Element Analysis) on all applicable components to verify they’re strong enough to last for many, many years. Below is a complete CAD model and the FEA for the throw adjustment arm with 50 lbf applied to the shortest throw position. This is the worst case scenario, so if it doesn’t fail here it won’t fail in the other positions.

Mazda Short Shifter under Pressure

With the 50 lbf applied to the arm, the maximum stress was ~10k psi which is great news. This component alone is 4 times stronger than it needs to be if you were able to apply 50 lbf to the arm.

One more shot of the short shifter

I have personally been using this shifter in my 2009 Speed3 for a month now and have nothing but great things to say. Don’t take it from me, though. Here is a quote from a beta tester:

I’m taking a spirited drive today to get a better feel for it. So far I’m enthusiastic about the (extreme) difference. When shifting with the OEM shifter the throw was so long that I spent a lot of effort synchronizing the clutch with the motion of shifting—essentially slipping the clutch while completing the motion of going into gear. With your short throw shifter the entire motion has changed dramatically and all I have to concentrate on is the clutch, and that’s been reduced by ~50%. I just throw it into gear and pop the clutch. It’s so stiff anyway and really likes to engage/disengage near the end when releasing pressure on the pedal that the motion becomes much more fluid. The shifter motion has gotten much tighter and requires (what feels like) more pressure to move between gears, but the motion itself has been reduced so much that it creates a sense of precision and removes (what felt like) sloppiness when using the OEM shifter. I’m sure that adjusting the height & throw from such an extreme position would reduce what I would describe as the rigidity of the shifts, although I intend to continue using it in the position we installed it.

My 2 cents so far. Overall I’d highly recommend.

Hope all is well,

Michael

So what are you waiting for? Take the leap, you won’t be disappointed!

-Barett, CS Engineering

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Top 7 Mazda Questions with Our Answers

Corksport Q&A

You had questions, we had answers. Here are the top 7 questions we found on Facebook, Instagram, and Twitter:

 

Question: What would be involved/required for CS to develop injectors for the MS3/6?DSC_2518

  • Questioner: Vincent Pham
  • Answer: Fuel injectors, especially direct injection, are complicated high-precision electromechanical devices. A project like this is outside the “normal range” for a small company like CorkSport; therefore we would have to team up with an injector manufacturer like Bosch to tackle this project. We would also need lots of money. Even with these huge hurdles to overcome we are investigating the project.

Question: What’s the most power you have seen a SkyActiv-G engine put down?Screen Shot 2015-01-21 at 12.34.32 PM

  • Questioner: Shane Foster
  • Answer: I haven’t heard of any high power SkyActiv-G and we probably won’t know for some time, unfortunately. Currently, the 2.5L SkyActiv-G engine produces 165hp at the crank, which is nothing to brag about in a market full of 300hp turbo 4-cylinders and 600hp V8’s. Although, the SkyActiv engines do have something to brag about; they are some of the most technologically advanced engines on the market. With a 14:1 compression ratio, direct injection, and variable valve timing that’s designed to run on 87 octane fuel; there is huge potential for power. CorkSport has an eye on this potential. For more in-depth information, check out the link below.

Question: Best way to clean carbon on the direct injected cars without pulling manifold and media blasting them?

  • Questioner: Alex Gonzalez
  • Answer: From my research and personal knowledge, everybody has their own method for better or for worse. One method is to use a ½” diameter hose attached to a shop vac and scrap away, but I don’t recommend that. Another method is to use the PCV port on the intake manifold to slowly suck Seafoam into the intake runners, but again I can’t say I recommend it. You can’t control how much or which ports it goes through and the idea of running something other than gasoline through the combustion chamber bothers me. Ultimately, you should remove the intake manifold and then clean it with a heavy-duty foaming engine cleaner. This will also give you a chance to inspect the intake valve and I do recommend purchasing an EGR delete kit.

Barett Oil ChangeQuestion: What oil should I use in my speed?

  • Questioner: Alex Duran
  • Answer: Alex you really want to stir that pot? O-well let’s give it a shot. I personally run Mobil-1 Full Synthetic and half a quart of Lucas Oil Stabilizer for 3000 miles. I’m not going to recommend a specific oil, but I will say this. You should run a full synthetic oil and quality oil filter. The oil should be SAE certified and be the manufacturer’s suggested viscosity or slightly thicker. I say slightly thicker because I have found good results when doing so with higher that factory horsepower setups and in severely worn engines.

Question: Think you guys will ever offer full performance engines and components. I.E. big valve head, billet cranks, high comp pistons, or a 2.5 bored to 2.7 with all that plus cams?

  • Questioner: Colt Krahwinkel
  • Answer: I’m going to assume this question is directed to all recent Mazda engines for the sake of variety. Unfortunately, we have no plans for the naturally aspirated SkyActiv-G engines other than bolt on’s; there just isn’t a big enough market for that investment. As for the DISI MZR engine, we have produced camshafts and plan to re-release those in the future. Other bolt on’s are either already done or planned, maybe even a turbo, but we don’t plan to get into the engine internals.

Question: How well might breathing mods affect power on the Mazda 2? Say CorkSport SRI, Headers, and CorkSport exhaust?axl-6-276-blue_installed

  • Questioner: Mike Wildt
  • Answer: With the combination of those, the highest gain I would expect is 20hp. The exhaust manifold would show the biggest gains, followed by the SRI. The exhaust system will give marginal gains, but a little grumble is always nice.

Question: Why do you highly recommend resonated over strait pipe? (Referring to the Gen2 Mazdaspeed 3).

  • Questioner: Phil Young
  • Answer: This can be a very biased opinion and is probably the most highly debated subject with all automotive enthusiasts. Despite that, I will try to throw in some facts. Personally, I can’t stand an exhaust system with an excessive drone. If you can barely hear your passenger, then what’s the point, right? That’s why resonators are important and why I should define the difference between resonators and mufflers. Resonators are typically a canister with strait through design and a perforated tube and packing material. Mufflers are typically canisters with chambers and baffles that divert flow. The resonator does not reduce the grumble of the exhaust that we love, it targets certain frequencies that cause the annoying drone. Mufflers are the opposite. Also, we have had many customers order the strait pipe exhaust system to later return it for the resonated exhaust.

Thank you for your questions and keep them coming. We’ll have a Q&A every month for your Mazda performance questions.

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Barett Strecker-01
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New Mazdaspeeds? You Heard it Here First!

Motortrend-Mazdaspeed-6-Article

 

Motortrend recently published this Article in their magazine. If you can see it, the article states that Mazda is planning a Mazdaspeed 3 in 2016, they list the details that have been floating around for months, 2.5L Skyactiv, Turbo, 300hp, AWD….. tell us something new!

We just want to point out that this is old news. In fact we even quoted Motortrend quoting their “source” back at the start of November saying the exact same thing!

Check out the post that is almost word for word the same article:

https://www.corksport.com/blog/lets-do-this-mazda-mazda-6-coupe-cx-3-mazdaspeed-2016/

As if that wasn’t enough, we also pointed out in August an article found a few places on the internet about a MS3 in 2017.

https://www.corksport.com/blog/mazdaspeed-3-coming-in-2017-with-awd/

In the article we say: “According to Ryan Beene at Autonews.com the next Mazdaspeed is planned for 2017.”

We also discuss the likelihood of AWD which we had previously pointed out in November of 2013! That’s over a year ago!

See that one here: https://www.corksport.com/blog/will-there-be-a-new-mazdaspeed-3-with-all-wheel-drive/

Now before you get upset that we are just pointing fingers and saying “we said it first” I hope you realize that this is actually a good thing! The more that we share a rumor, and so does other reputable sources like Jalopnik, Motortrend, AutoNews and more, the more credibility it gets! I doubt that the rumors of AWD, 300hp and it being a MS3 are that unlikely when it seems everyone is reporting on them.

So, more props to you MotorTrend! We are right there with you and look forward to 2016, 2017 and all the new cars Mazda brings us!

 

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