We’re Listening… Big Turbo Products !!

Got Boost ?

We’ve heard through the grapevine that some people think of CorkSport as a “Bolt-On” company. NO WAY! It’s often said that you need to go to XYZ or ABC or some other micro-tuner for big turbo (BT) products.

It’s true that we don’t yet offer a big MAF intake or upgraded manifolds and the like for the BT crowd. This is a matter of economics not passion or engineering capability. Fortunately for all of us, more and more Mazdaspeed3 owners are pushing towards 400 WHP and beyond. We believe there are enough of you out there to support some big time products. Before we get into those, let’s revisit a collection of our products that we’ve released in the last year that no other Mazda performance company can touch. Most can’t even check one of these parts off their list.

Fuel Pump Internals
Patent Pending BPV
Adjustable Struts
Lowering Springs
Coil-over Suspension
Big Brake Kit
Why Modify Book
Brake Pads, Panel Filter, Toe Arms, Hood Struts, Coolant Tank, and many more…

No-one in this market innovates at the pace we do at CorkSport. No-one in this market comes close to releasing the quantity of products we do at CorkSport. Check out what’s in the pipeline* for our BT friends.

CorkSport Intake Manifold V1

CorkSport Exhaust Manifold

CorkSport 3.0” Big-MAF Intake

CorkSport Camshafts

We are also working on CorkSport 3.5” Big-MAF intake and CorkSport Fuel Injectors for MZR-DISI among many other projects.

We are a dedicated Mazda performance company. You’ll find no Ford, Subaru, BMW or other platforms on our website. Our profits go back into making more Mazda parts. That’s it.

You told us you want to go BT with CorkSport. We’re listening.

As always, we appreciate your business and feedback. Reach out!

Richard Harris

President

* Keep in mind that not all products in development make it to retail. Sometimes we develop a part and find there is no real value and abandon it – TMIC cold-pipe. Other times, the cost to launch a new part is such that we can’t hit a price point that you will accept.

October 23, 2013January 4, 2020

The Fuel Pump Finale… (Sort Of)

How To Create The Best Pump on the Market

With our fuel pump design complete (link to fuel pump blogs 1,2,3,4), we now turned our attention to the details. We wanted a coating to protect the piston and decrease friction during operation. After testing dozens of compounds, we settled on a very strong coating that is applied with a proprietary process. This process allows for an exceptional bond with the metal, lower static friction, and increases the surface hardness. Before applying the coating however, we wanted to make sure we had the best part possible underneath it. Imagine having an orange that is covered in titanium. The surface might be incredibly hard, but with no substance to back that up you will eventually lose the shape.

After choosing a very strong alloy for our internals, we then machine their tolerances to an incredible 6 microns! To make sure the tolerances are paired for life, we serialize the parts to prevent any issues and to track the life of the pumps. We then surface treat the pumps to achieve the alloys maximum strength; only after the maximum hardness is achieved do we apply our surface treatments to bring the overall durability to an even higher level.

Many companies would be finished at this point but, at CorkSport, our research has shown us that when a coating is applied it is very difficult to maintain a smooth surface. In fact, we found that the coating has many microscopic hills and valleys. There would be no reason for us to go through all the work of having incredible tolerances if we were just going to ruin them with an uneven coating. In order to correct this, the pistons are then re-machined back to their original single micron tolerance. The CorkSport Fuel Pump Internals are the lightest aftermarket kit on the market for faster response and decreased cam wear. At this point it may seem like we are flying this pump to Mars but we just wanted to make the best part on the market, and it worked.

Pump More Than Any Other Kit Available

All of this adds up to an improved pumping volume that is over 8% higher than all other pumps we tested and 50% larger capacity than the stock pump. When other pumps are losing efficiency because of their design or tolerances, ours is just hitting its stride. That difference in the real world is going to be higher HP numbers, safer air/fuel ratios and the ability to go that much further without worrying about your fuel supply.

Because of the increase in fuel we highly recommend that you get a new tune for your car we have made a combo deal to save some money here.

How to Buy the Best Fuel Pump Internals

Now that the cat is out of the bag we can let you know a few more things.

Our first batch is very limited and we want to give everyone that has been waiting a fair shot at getting one. We will release these parts for Pre-Order on November 1^st. The Pre-Order will be limited to the first 100 paid orders or November 14^th, whichever comes first.

The CorkSport High Pressure Fuel Pump internals include a collectable aluminum box with:

Full color instructions
Stainless Steel Installation Tool (That also doubles as a keychain bottle opener!)
Anodized Aluminum Installation Sleeve
CorkSport USB drive with Installation Video, Promotional Video and Other Bonus Material
CorkSport Precision Fuel Pump Internals (including higher rate spring)
Retaining Hardware

The Pre-Order will go live on November 1^st at 12am Pacific Standard Time and will remain up until the initial 100 orders have been placed. Unfortunately these are the only internals we will offer for 2013 so if you miss the pre-order you will have to wait until next year to get the best fuel pump upgrade on the market.

October 17, 2013January 4, 2020

The 33% Faster, 50% Smaller, 100% More Innovative CorkSport Bypass Valve

The CorkSport Mazdaspeed MZR Bypass Valve (Patent Pending)

With the new Patent Pending CorkSport Mazdaspeed MZR Bypass Valve you can have all the goodies of an aftermarket Bypass Valve, in a smaller size. By using a unique patent pending wave spring design, CorkSport was able to shrink the body of our bypass valve to almost half the size of stock. Along with this, the wave spring was tested to respond 33% faster than a stock valve. Since the blow off valve is a safety feature to protect the turbo from premature wear, this increase in acceleration can help increase the longevity of the turbo and the system as a whole. For more about all the innovations in the CorkSport bypass valve, click here.

So why do you need to upgrade? Well, the stock Bypass Valve is pretty good, but it falls short in two areas. When it comes to holding boost the stock Bypass Valve often will start leaking at anywhere upwards of 17psi. If you plan on having your boost much higher than stock you could have issues with leaks. Of course, you also upgrade a bypass valve to get that unique sound.

While the unique patent pending CorkSport Mazdaspeed MZR Bypass Valve will provide both a unique sound and hold more boost, our BPV will also provide some other key benefits that, until now, have been pretty much ignored by others.

The CorkSport MZR Bypass valve utilizes a compact wave style spring which allows the stock valve size to be decreased by half. This patent pending design allows room for other engine upgrades such as Big Intakes, Airboxes, Front Mount Intercooler setups and more. Using a wave style spring that is 20mm in height compared to the stock 40mm not only enabled us to shrink the overall size of the valve, but also shrinks response time to lightning quick speeds. Though both the stock spring and our wave spring provide the same force and move the same distance before coil-bind, a smaller wave style spring can respond up to 33% faster.

A smaller spring allowed us to decrease the overall size of the piston while still pushing the piston area out to ensure a larger venting area. This reduces the time it takes to vent air and allows any turbo, especially larger turbos, to vent more efficiently.

No matter which benefit is more important to you, whether you value long turbo life, unique sound, more engine space, or holding higher boost, the CorkSport Mazdaspeed MZR Bypass Valve should be your first choice.

To Learn More or Purchase the CorkSport Mazdaspeed MZR Bypass Valve here: https://www.corksport.com/corksport-mazdaspeed-mzr-bypass-valve.html

October 15, 2013February 28, 2018

Fuel Pump Comparison Part 4 (Bombs Away!)

We know by now that adding power to your Mazda is fairly straightforward up to a certain point. However, sooner or later, that hunger for power means you’re going to need to step up to a new fuel pump that can flow more fuel. By seeing that most of the fuel pumps on the market were largely the same, we decided to see what kind of innovations we could bring to the table. At this point we had learned volumes about the pumps on the market through our research and decided to engineer a new set of pump internals that focused on everything that we had learned.

We know this is possibly the worst kept secret since Area 51, but we started engineering fuel pump internals over 2 years ago and we aim to show you why ours is worth the wait.

We didn’t just set out to make another pump; the market has plenty of those. We set out to make the best Mazda fuel pump upgrade on the market specifically for Mazdas from a company that ONLY makes parts for Mazdas.

We started by researching many different technologies and engineering ideas in the pressure ranges experienced in these fuel pumps. We purchased every kit on the market and a brand new replacement from Mazda to test. The results from some of those tests can be found here (Link to blogs 1,2, and 3). After agreeing that 9.8mm was the maximum size we could attempt for the piston without making the sleeve wall too thin, we could start engineering the rest of the part.

We then built all the internals available in SolidWorks and tested the efficiency of them all for flow design and volume. This was merely the beginning of our design phase but helped us realize many great ideas (as well as a few not so great ones). We ended up with a design unlike any other on the market that, according to the data, would be more efficient than anything on the market.

With the increase in flow and efficiency we knew that our design could also benefit from a stiffer spring rate for the pump. That would enable higher RPM’s and improved cam wear over the life of the pump. Since we would be flowing more, the pressure on the pump would be greater than ever, the stiffer spring was just good insurance to get the power we needed even past the stock redline.

During our testing we also discovered the keeper assembly used by the factory is no accident. Many of the other pumps on the market use a keeper system similar to an intake or exhaust valve. This style does a fantastic job of locking the piston in place, but creates a few issues of its own. Because of the flow of fuel, the piston rides one side of the sleeve more than the other; over time, this will wear more into the piston which will affect clearances and efficiency. To prevent this, the factory style keeper allows the piston to spin as the spring moves up and down. That led us to choose the factory style retainer. We didn’t want to guess on either design without proof of our theory so we produced samples of both styles to prove wear differences and address installation challenges related to both styles.

Now that the cat is out of the bag, we’ll have just one more fuel pump blog next week with a very exciting limited offer. Stay tuned as CorkSport is about to take Mazda performance one step higher!

September 16, 2013

Representing CorkSport Mazda Performance

Representing CorkSport Mazda Performance.

Since starting here at CorkSport HQ, I find myself searching the lanes of traffic for Mazdas. I can’t deny that it gets my heart pumping a little bit when I see a Speed3, but that’s merely because I have a preference for them and the “zoom-zoom” effect.

What keeps me looking is that I don’t always see Mazdas of what I’ll call the “proper persuasion”. It may just be a Pacific Northwest thing, but there are a lot of sexy performance cars roaming the streets disguised as family vehicles. Now don’t get me wrong, a family car is always necessary, but after seeing what the enthusiasts are capable of, I get a little disappointed when I don’t see a CorkSport branded vehicle behind every Mazda emblem.

Over Labor Day weekend I was driving home from camping and having a conversation with a fellow car enthusiast (he’s into Mitsubishis, yuck) about how often we see cars “repping” their favorite performance brand. He was actually doing a great job of making me defensive, saying that he’d never seen a good looking performance Mazda. He said it was a rare occurrence out here to see a clean/stance one and then for it to also be repping CorkSport, “like seeking unicorn’s”. I was disagreeing with all that I had, and yes I mean that in reference to volume control.

We were in a deep, what I’ll refer to as an, “elevated and passionate” conversation, when low and behold, there in the lane just left of us, was a tiny 6” decal on the back right of a very clean Speed3 (Gen2). A perfectly pitched screech of “TOLD YOU SO” bellowed from my mouth, followed by a quick cell phone pic and a good long laugh at how “I (Kim) am always right, get used to it.”

Since then, we have found and rewarded the owner of this beautiful beast https://www.facebook.com/photo.php?fbid=10151905810739257&set=a.317272679256.181853.126409094256&type=1&theater, but it got a great conversation going in the office of “where is the best spot to place a decal?”

So, this is the question I pose to you, our readers: “Where do you think is the perfect spot to rep your favorite performance brand?” I prefer them to go along with the elegant lines of the car, but others say that having them stand against those brings a slick look as well. What do you think?

Here are some of the pictures that we have seen the in past, please feel free to post yours so we can check it out!

Can’t wait to see what you all show us!

Sincerely yours,

The very passionate and boisterous CorkSport Customer Service Representative,

Kim