Keeping Your Mazda Clean During This Winter Season

CorkSport Recommendations for Keeping Your Mazda Clean During The Winter Season

How many of our CorkSport family members have more product for their paint jobs on their Mazda’s than their own bodies? I know that we at CorkSport have more product than we can count with all of our fingers and toes. We enjoy having that smooth paint job with no imperfections and a paint job that beads up water with ease.

So how do we keep our cars paint baby butt smooth with all of the Pacific Northwest rain, and snow?

We make sure to do preventative paint correction so when the weather breaks, and the sun shines, we know our cars will look above anyone else. I wanted to take a little bit of time to make sure that CorkSport family members could see what we do to make sure our cars stay clean during the nasty winter seasons.

Before working for CorkSport, I managed a full-service car wash/detail shop for about eight years. There is always a common misconception that at least keeping the car clean will keep the paint looking good for long periods of time.

However, that is not correct. A car’s paint has polymers which over time dry out and lead to fading of the paint. This is why I recommend that if you are going to use a self-serve car wash, or an auto car wash, to make sure you use triple foam polish. The triple foam will re-condition the paint, and it will also leave a nice shine behind after the car has been dried. Also, any person who uses triple foam polish on their car will notice that dirt and grime come off the car easier the next time you clean it. Keeping the clear coat nice and fresh will result in less time cleaning and a much cleaner car over time. If you love your Mazda, make sure to use triple foam when you can!

Adding triple foam to your car wash procedure is a start, but it doesn’t stop there. I recommend to at least hand-wax your car twice a year. Waxing the car will remove things like tree sap, bird poop, light water spotting, and any other imperfections that may be seen while daily driving. It is very important to remove those imperfections because the longer they sit on the paint, the faster the clear coat starts to break down. As you can imagine, the chemicals put down on the road during winter can have a dramatic effect on the luster of the car, and before you know it you have fading paint.


As most of you know, mud flaps are normally associated with a rally car. I think we can all agree that a lot of Mazda owners also use them. I decided to use mud flaps not because I wanted to go tear up the dirt, but because I knew that it would keep my side skirts, and rear hatch much cleaner. After having the mud flaps installed, and moving to Washington where it rains eight months out of the year, I realized that mud flaps do in fact make a huge difference in keeping the car clean.

Additionally, the side skirts will see less wear and tear from junk on the roads keeping the side of the car in much better condition. When looking at getting mud flaps, make sure you get ones made out of poly, so they don’t bend over time.

The most important thing to have when owning a dope ride would be to have a garage to park her in. I know it might be a struggle, but get that garage organized, make some room, and fit your baby inside a closed building during the winter. The last thing you want is falling leaves, bird poop, tree sap, etc. to fall onto the car and sit on the paint for multiple months. Also, having that garage means you can now spend countless hours working on the car without having to go anywhere! Plus we all know that when you tell the significant other it will only take four hours to complete an install, we all know that it will take eight!

The cleaner you keep the car, the easier it is to correct the paint when the weather breaks. The end goal is to pull into the car wash, put the soap on the car, and watch the dirt melt off the car. If you have achieved this level of luster, then you have done a very good job at keeping the car well-kept during the nasty winter season!

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Mazda 3 TCR

An interesting article popped up a few days ago in which John Dagy, a journalist with Sportscar365, was discussing the TCR class of cars with John Doonan, the head of Mazda Motorsports program.

I have been following the TCR series for a while now with some interest in it as the car Mazda offers that fits best is the Mazda 3, and I enjoy the time I have had racing CorkSport’s Gen3 Mazda 3.

What is nice about the series is that it is meant to race four-door saloons, all with a 2.0 turbo motor and a price-capped ceiling of 135,000.  Most people would freak out a bit with that price but what you are getting is a fully developed car with a spec sheet.  Each manufacturer designates a builder, whether themselves or a shop, to assemble the cars and provide support.

Mazda is in an interesting spot; they have their successful Global MX5 cup series and the IMSA Prototypes with Joest, but there is a middle-ground hole that has been filled with the older NC Miatas.  With the NCs not being a current production model, it makes sense to get something in there to fill in the blanks.

 In the past, Mazda had used the Mazdaspeed 3 as the basis, and it did well capturing the championships in PWC and IMSA ST class, but the lack of a turbo model makes this a challenge.

One option out there would be to use one of our upcoming 2.5 Skyactiv Mazda 3 turbo kits and bridge the gap so to speak to have a powerplant.  Granted the turbo kit is for the 2.5 but with enough encouragement and feedback from people, the 2.0 kit is looking likely.

Work on some aero and really good suspension, and you would be set.  Maybe I am just daydreaming too much at work again….

-Derrick

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The First and Only Performance Mazdaspeed Throttle Body with NO Sacrifices

Mazdaspeed3 intake manifold and throttle body installed

Many have tried, but few have succeeded to retrofit or modify an existing throttle body to work with the Mazdaspeed DISI MZR platform.

As you know, CorkSport does things a little differently, and as a result, we started from the ground up to create the best performance throttle body possible with no sacrifices to drivability or reliability. Introducing the CorkSport 72mm Throttle Body for 2007-2013 Mazdaspeed 3, 2006-2007 Mazdaspeed 6, and 2007-2012 Mazda CX-7.

Starting from the ground up means 100% brand new parts, no reworked or refurbished components anywhere.  

We start with an aluminum investment cast body that is made to our specific design specifications.

A flat faced throttle plate is added to gain a little bit of extra flow by avoiding the bump of a traditional round pivot shaft.

Finally, new electronics are added that are based upon OE logic to avoid any tuning and calibration issues.

To retain easy installation, we knew we had to keep the OE bolt pattern. With this, we wanted to maximize the throttle plate diameter for maximum flow. We ended up increasing from 60mm to 72mm. This may not sound like a huge increase, but the OE Throttle Body fits inside the CorkSport Throttle Body with plenty of room! The 72mm size also fits well with both 3” and 2.5” intercooler piping to fit almost any TMIC or FMIC setup. Finally, we did away with the OE gasket (which is too small anyway) and replaced it with a durable O-ring that will hold up to oil, gasoline, methanol, and other fueling options that it may come in contact with.


The CorkSport Throttle Body underwent extensive testing to ensure that it will not fail during daily use and to ensure it performs as well as we expect. The throttle plate underwent endurance testing to validate the D-shaped pivot can stand the test of time. During flow bench testing, we found that the CS flows about 150CFM (~33%) better than the OE throttle body when 75% open (accelerator pedal fully depressed).

Check out the graph below for the full data.
Mazdaspeed Throttle Bdy Graph for flowbench testing

In daily driving testing, we noticed better throttle response with no CEL or choppiness. In power testing with a midsized turbo (~GT30 size) we found the throttle body caused faster spool, but when we moved to a big turbo, things got interesting. With a GT35R, the CorkSport Throttle Body caused 100-200RPM faster spooling and an increase in power. Check out the dyno graph down below to see the difference between the CS Throttle body (blue) and the OE throttle body (green).

Dyno stats for the Mazdaspeed 3 Throttle Body

Each throttle body ships with fresh stainless steel mounting hardware, a 3” stainless t-bolt clamp, and your choice of silicone. We have options for FMIC, Mazdaspeed 3 TMIC (which also works for you CX-7 guys), and Mazdaspeed 6 TMIC.

Mazdaspeed Intake Manifold with Throttle Body
If you’re looking to take your Mazdaspeed3, Mazdaspeed6, or CX-7 to the next level, or squeeze that last bit of power out of your big turbo build, the CorkSport Throttle Body can help you meet your goals.

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Product Release: 2010-2013 Mazdaspeed 3 Exhaust Mid Pipe

CorkSport is happy to announce the release of our long awaited 2010-2013 Mazdaspeed 3 Exhaust Mid Pipe. Designed by our engineers to be a simple, bolt on upgrade for your Mazdaspeed 3. The CorkSport mid pipe changes the exhaust note only slightly and gives a pleasant tone unlike some Mazdaspeed exhausts on the market which can sound hollow and buzzy. The exhaust features 80mm piping and a single resonator, all constructed from T304 Stainless Steel.

Mazdaspeed 3 exhaust mid pipe

As with all of our CorkSport exhaust components, the Mazdaspeed 3 mid pipe features mandrel bent, polished stainless steel T304 construction for corrosion resistance and a clean stylish look. It has a distinctive performance sound that is mild but noticeable at cruise and idle but packs a bit more of a rumble when you’re really getting on the throttle.

For more information please visit our Mazdaspeed 3 Exhaust Mid Pipe product listing for details.

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New Product: Mazdaspeed Camshafts for DISI MZR Motor

Mazdaspeed camshaft

After multiple years of testing, design and research, CorkSport is proud to announce its release of camshafts specifically designed around the MZR DISI platform. This kit is engineered to reliably provide increased power and torque without lower rpm sacrifices.

The turbocharged MZR DISI engine was first introduced in the 2006-2007 Mazdaspeed6 and was later put in the 2007-2013 Mazdaspeed3. This engine has a High-Pressure Fuel Pump (HPFP) that is driven off the intake camshaft. Other MZR engines use different camshafts and don’t have a HPFP lobe to run the fuel pump. This has been a limitation in the market since the engines introduction.

Camshaft Basics

In order to understand the basics you need to know some camshaft terminology. The most common terms are lobe, lift, duration and base circle.

Common Drawing of Camshaft Terminology
Common Drawing of Camshaft Terminology
  • Base Circle – The circle on the backside of the lobe. When the base circle faces the valve the valve is closed.
  • Lobe – The lobe is the portion of the camshaft surface that is not the base circle. This is when the valve is opening or closing.
Camshaft base circle and lobe
  • Lift – The distance between the base circle and the top of the lobe. This will be the amount the valve is allowed to open.
  • Duration – The distance, in degrees, that the camshaft is in the lift section. This controls the time that the valve will be open. This is shown in the diagram from A to B.

MZR Flow Testing

The first thing to do was flow test the head to figure out where restrictions might occur. To flow test, a constant vacuum was applied through the head and while slowly opening the valves. This is similar to what the engine is doing while running.

Intake lift

The factory intake ports do not flow much air above 0.350” of lift on the flow bench. The factory camshaft runs rough at 0.370” of lift. Shown in the graph below, minimal flow was increased between 0.350” and 0.400” on the factory head.

Intake Ports of MZR DISI Head graph
Intake Ports of MZR DISI Head

Porting is the process of modifying the intake and exhaust ports of an internal combustion engine to improve the quality and quantity of the air flow. After porting the head, there were significant increases in flow, but around 0.400” of lift there was again minimal increase in flow, with more lift. Testing suggests a proper maximum lift of 0.390” for the intake camshaft. Factory heads or ones with a large port should show gains from this increase in lift.

Why Stop at 0.390”?

More lift above 0.390” would require very extensive head work to gain much more power. Another downside of going above 0.390” lift is the valves will require stronger valve springs to maintain proper valve operation at high boost or high rpm. Upgraded valve springs should not be required for a factory head with 0.390” of lift camshafts.

Exhaust lift

A similar process to that described during the intake lift process was used on the exhaust ports and an optimal lift of 0.355” was chosen. For comparison, the factory runs 0.321” lift on the camshaft.

Exhaust Ports of MZR DISI Head
Exhaust Ports of MZR DISI Head

Limitations of Existing Options

The factory camshafts were designed around a compromise of performance and emissions; from that design criteria, there is still more power and torque available. The reader can now understand why increased lift and duration can release this power. There are limited options to increase lift and duration on the MZR DISI engine.

Reground Factory Camshafts

In order to increase lift and duration on a reground camshaft, the factory camshaft must be welded and reground to the new profile, but commonly the base circle is reduced. This allows the lift to increase and also the duration to be adjusted.

There are limitations with this approach. When reducing the base circle, many other parts in the head will have to make up for the amount ground away. It is essentially limited to the amount ground away. It is also limited by the duration because the profile must fit within the factory profile design.

In order to regrind a camshaft it must be removed from the engine or a new camshaft must be bought. A used camshaft can have wear that cannot be fixed. Buying new camshafts to send out is expensive and adds to the total cost of installing the camshafts.

Aftermarket Camshafts

The only aftermarket camshafts currently available are not designed for the MZR DISI engine. This means the intake camshaft does not have the ability to run the HPFP.

The existing camshafts for the MZR engine were also designed around naturally aspirated (non-turbocharged) engines, so the duration, lift, and overlap between the intake and exhaust camshafts are not optimal for forced induction applications.

The best option to upgrade camshafts is to buy those designed and made for the MZR DISI engine specifically.

Camshaft Design

In order to start testing camshafts on the car, a blank camshaft is needed. This requires making a mold and casting a generic camshaft from a mold. Then the bearing services were machined to factory specs and after that a few dozen durations, ramp rates, and overlaps based on the engines natural pumping ability were chosen.

Blank Camshaft with Bearing Surfaces Ground
Blank Camshaft with Bearing Surfaces Ground

After carefully grinding all of the blanks, it was time to dyno the engine and determine the difference in power and torque.

An engine is basically a vacuum pump with the camshaft helping determine at what rpm the pump is efficient. Camshafts allow the power under the curve to be manipulated. If you have ever taken a calculus or thermodynamics class you might have flashbacks.

Power/Torque Factory Camshaft vs CorkSport Camshaft
Power/Torque Factory Camshaft vs CorkSport Camshaft

Potential variations in the engine tune, fuel, outside temperature, and other factors were monitored. The result is clear improvements in power and torque throughout the rpm range. The final design was chosen to limit lower rpm power decrease with a large band of power improvement over 4,500 rpm.

Exhaust Camshaft Comparison

Further examination of the exhaust lobe design is a good example of where the power comes from. When looking at the lift versus degrees as the cam spins, the changes to the lobe profile become apparent.

Exhaust Camshaft Design
Exhaust Camshaft Design

This change allows the camshaft to lift the valve more and longer. This allows more air to flow out of the engine.

Intake and Exhaust Relationship

The intake camshaft is electronically controlled. With additional tuning, turbo spool and power can be increased by controlling the overlap between the intake and exhaust camshafts. Overlap is the time when both intake and exhaust are open at the same time. Typically in a turbo car overlap is much smaller than in naturally aspirated cars. Below shows intake and exhaust camshafts placed over each other and the area that would be considered overlap.

Diagram of Overlap
Diagram of Overlap

Fuel Pump Lobe

Recall the intake camshaft drives the mechanical HPFP. In order to allow the end user to have the best camshaft possible and also have reliable fueling and limited wear the fuel pump lobe on the CorkSport intake camshaft is ground to match the factory camshaft lobe and then rechecked to ensure no clearance issues.

Mazdaspeed racing camshaft

Installation:

The installation of camshafts in the Mazda MZR engine is not easy. Camshaft upgrades should be considered by an experienced enthusiast or professional installation is appropriate. To aid an experienced installer, detailed installation instructions are provided. Successful installation is supported in two different ways.

  • Color installation instructions
  • Excel Tappet guide available for download online

The CorkSport Camshafts for DISI MZR feature:

  • Created from brand new castings.
  • Break-In coating included on lobes to extend life of camshaft.
  • Designed exclusively for the MZR DISI engine.

Extensive testing to determine optimal camshaft design then manufactured to exact tolerance.