CorkSport Injector Puller

For the Mazdaspeed 3, Mazdaspeed 6 & CX7

After years of popular requests, we have something that we are very excited to announce! The CorkSport Injector Puller is here, and ready to assist you with your DIY, or shop needs.

With great power, comes great responsibility! And owning a Mazdaspeed may have made you aware by now of how troublesome removing a GDI injector can be. We designed this to assist you.

YOU CAN NOW SAY GOODBYE TO:
  • Twisting a seized injector until it breaks loose
  • Rigging up some method to pull or pry out the injector
  • Beat up hands
  • Beat up injectors
  • Hours of lost time

Now, I know what you are thinking: we may be late to the party. We are aware that we are not the first ones to make such a tool, however, we wanted to ensure that we made one of the highest quality that can be used time and time again. We love that you guys buy our seals, and we wanted to help ease the installation as much as possible.

With its stainless construction, Nator can truly make use of this when it gets passed around, because it won’t deteriorate with use.

As the OE seals fail, carbon starts to built up around the injector and seal and really locks that sucker in there over time. Sometimes an injector has to be sacrificed as seen above. But, It’s amazing how much easier the proper tool can make the job.

Although it may resemble a shake weight a bit, its just your normal slide hammer style tool with a custom head designed to perfeclty fit the DISI Injector.

HOW TO USE:

  1. Take off O-Rings that will be on the tip of the Injector where it goes into the Fuel Rail. Be sure to store those in a safe place.
  2. Slide the head of the tool into position as shown.
  3. You will then put tension on the tool pulling backwards.
  4. Use your other hand to slide the hammer backwards until it hits the lock nut on the back. Repeat until the stubborn injector finally breaks free.

– The CorkSport Team

Be sure to check out our full product video on YouTube and remember to subscribe!

 

CorkSport BIG Turbo for the Mazdaspeed & CX-7

Mazdaspeed 3 big turbo upgrade

Good day boosted enthusiast!

We wanted to take some time to give you all a quick update on one of the many projects we have brewing up here at CorkSport Headquarters.

The project I’m referencing, in general, is our 2nd turbocharger upgrade for the Mazdaspeed 3, Mazdaspeed 6, and CX-7. This unit is a substantial upgrade over our current 18G turbocharger. This Turbo will cater to those looking to take their performance and power goals to a higher level.

Not only will it be capable of putting you well into the 465whp range but this CorkSport Turbo upgrade will be able to do it without giving up on reliability and throttle response.  

It will be very beneficial to those who have mildly-built blocks and a supporting fuel system that will allow them to get higher in the HP range.

So, let’s talk about some of the features you can expect on the upgrade and why we decided to utilize them.

Let’s start at the heart of the Turbocharger.

The new CorkSport Mazdaspeed turbo will take full use of a GTX3076R center housing and rotating assembly (CHRA). The unit is equipped with a fully sealed ball-bearing cartridge, which is a nice upgrade when compared to a standard journal-bearing unit. We chose to go with a ball-bearing unit for a few reasons.

  1. The enclosed design of a ball bearing system allows us to eliminate the need for a thrust bearing, which can account for about 40% of the bearing system drag on the turbo rotor assembly.
  2. Ball bearings reduce the viscous drag, which allows a ball-bearing unit the ability to spool up about 15% faster than its journal-bearing equivalent.

The next thing you will notice on the new Mazdaspeed Turbocharger upgrade is the holes that are drilled into the compressor cover. These little holes are known as anti-surge ports and are intended to expand the turbochargers compressor map. The ports function to move the surge line further left on the compressor map which gives the Mazdaspeed turbo some more headroom before it falls out of its efficiency island. Anti-surge ports are becoming increasingly popular in modern performance turbochargers and with great reason. They offer some unique benefits as mentioned and will be fully integrated into our unit.

Last but not least, as with our CorkSport Turbo, this bigger Mazdaspeed Turbo will once-again be a true drop-in unit; minus the 4” compressor inlet.

There will be no cutting, modifying, sourcing oil and coolant lines, running to the store to buy couplers, etc. This unit will come with everything you need to have a trouble-free install. As with the current CorkSport 18G turbocharger, the new Garrett-based design will come with all studs, gaskets, washers, and knowledge that you need to have a nice weekend install.

So keep your eyes peeled as we get closer to delivering more performance for the Mazda community!

– The CorkSport Team

SOURCES: Miller, Jay K. Turbo: Real World High-Performance Turbocharger Systems. CarTech, 2008.

What’s in the Pipeline for the 2014+ Mazda3?

Here at CorkSport, we are always working toward the next new product. We create our catalog just like you build your cars. Since there’s so much in development, we thought we would give you all a glimpse into what’s coming for the 2014+ GEN3 Mazda 3.

2.5L SkyActiv-G Turbo Kit

Let’s start with the big one since you’ve all been asking for updates: the 2.5 Liter Skyactive Turbo Kit. We are still making steady progress and are more excited than ever for this Mazda3 Turbo. Our functional turbo kit prototypes are slowly starting to arrive, meaning we are inching closer and closer to having our Mazda3 test car on the dyno (with added turbo noises). Stay tuned folks; this is going to be a fun one!

2014-2016 Mazda 3/6/CX-5 Motor Mounts

 

We already showed you the new and improved CorkSport Rear Motor Mount, but there’s more to come with the CorkSport Transmission Motor Mount. Check out the CAD model above to see what we’re talking about. Keep tabs on the CS blog for more info on the design and function of this motor mount soon.

2014-2016 Mazda 3 Skid Tray

The CorkSport skid trays have been consistently requested for the Mazdaspeed models; so much, that we brought them back for both the Mazdaspeed3 and the Mazdaspeed6. Now we are providing the same benefits to Mazda3 owners. We just received and test fit our first prototype skidplate, and it’s looking very promising moving forward.

2014+ Mazda 3 Suspension Kit

Need some extra handling and style for your Mazda3 but don’t want the hassle of lowering springs? We have created a kit that includes the CorkSport lowering springs, adjustable shocks/struts, and camber plates all assembled with OE accessories and ready to install. No spring compressors needed, for ease of installation. Coming soon…

2014+ Mazda 3 Front Sway Bar

Reducing overall roll or “sway” can drastically change your Mazda’s handling characteristics. We should be receiving our first prototype to test fit on our Mazda3 any day now are excited to see how it complements the CorkSport rear sway bar. Oh, and the new front sway bar is 3-way adjustable just like our ND Miata sway bars!

2014-2016 Mazda 3 Steering Wheel

Last, but not least, our leather steering wheel will be making a comeback in the coming months. Featuring a similar profile to the CorkSport Mazdaspeed3 steering wheels, it is designed to increase confidence in both aggressive and daily driving while staying comfortable and stylish.

As you can see, we are staying busy with the newest generations of Mazda here at CorkSport, but that doesn’t mean it’s the only thing we are focused on.

We still have plenty of upcoming products for you Mazdaspeed guys and gals, and for some platforms you may not be expecting. Keep tabs on the CS blog, Instagram and Facebook page to make sure you don’t miss anything!

Until next time,

-Daniel @ CorkSport

The Mazda 3 Rear Motor Mount 2.0: Back & Better

2014 Mazda 3 rear engine mount upgrade

We here at CorkSport are proud to announce the relaunch of the Mazda 3 Rear Motor Mount.

Yes, you read that correct, this is a re-launch. At CorkSport we push ourselves to design and develop new and interesting products every day, with that, we try new and innovative manufacturing designs and methods in an attempt to create exceptional, competitive, cost-effective products for our loyal customers.

Sometimes those new and innovative manufacturing methods end up not being as awesome as we originally expected. This is just part of the designing and learning process. Let’s get into the details.

The original, let’s call it V1, Mazda3 RMM used a new-to-us manufacturing method of applying the polyurethane to the billet aluminum body called vulcanizing. The billet aluminum body and the steel sleeves are mounted in a fixture then liquid polyurethane was poured into the assembly and cooled until the polyurethane had set to the final hardness.  This process appeared to be very promising; each part was set up identically, it was nearly impossible to have any missing parts not sent to you, and most importantly the polyurethane was adhered to the billet aluminum body and therefore could not fall out.  More on that last bit later.

We moved forward with the manufacturing method and had a few samples made with various polyurethane durometers ranging from 60A to 80A.  After various testing, we determined that 70A was the best compromise of response and NVH (Noise, Vibration, Harshness) experienced by the driver. We continued testing for a few months to verify long-term durability and found no issues.  Hooray! We moved forward with production to get this new great Mazda6 RMM out the door to you.

Unfortunately, it appears that our testing period just wasn’t quite long enough.  Eventually, the polyurethane would fail but fail in a style we had never experienced before.  Long story short, polyurethane has excellent compression strength compared to the tensile strength.  The polyurethane was being pulled/split apart due to the forces of the engine.  

Now we had a few options of how to redesign the Mazda 6 Rear Motor Mount after going through the failure analysis.  

  • We could have simply stuck with the same design and just increased the stiffness of the polyurethane.  Increasing the durometer rating of the poly increases the tensile strength, but this would have resulted in an unsatisfactory driving experience for you which was unacceptable.  
  • The other option was to start from scratch again to create a new design that did not compromise the driving experience or the durability; with challenge comes innovation.

Again we went through many different designs, with the greatest challenge coming in the form of retaining the polyurethane pucks.  Typically the polyurethane pucks are retained by whatever the mount is bolting to, but with the Mazda motor mount, the steel sleeves extend far past the outer edge of the polyurethane pucks.  This leaves the pucks free to slide out of the billet aluminum body and cause a major failure.  

Using the conventional polyurethane puck style, we developed a design that would work, but more than doubled the number of parts needed which increased the chance for something to go wrong and drives up the cost.  This design is shown below:

 

The red arrows show the direction the conventional polyurethane puck would slide out of the body.  The red circles show the puck retention system to hold the washer and pucks in the body.  This retention design required many parts to be successful.

With the cost going through the roof we had to go back to the drawing board. There had to be a better way… and there was.  

The third major iteration shown above solved the problems of the V2 design and got us away from the vulcanized polyurethane of the V1 design.  Things were looking good.  With the V3 design, the polyurethane pucks are pressed into the billet aluminum body.  The pucks have ribs, shown with the red circles that are just large enough to keep the puck in place, but small enough to let the puck be pressed into the body.  

With this, we were able to make some clever designs to the RMM to keep it centered in the engine and chassis brackets on the vehicle.  The smaller diameter puck extends out to the ends of the steel sleeves; this keeps the entire rear motor mount centered.  The large diameter puck retains itself in the body and allows the associated steel sleeve free to slide for easy installation; shown with the red arrows.

Now… does it work? YES! Pretty fantastically, we might add!  

We have had this design on a handful of vehicles, one of those being the CorkSport Mazda 3 Racecar during the SCCA Run-Offs at Indianapolis Speedway.  Other than some dirt and grime, the tested RMM looks great.  

You were probably expecting this blog to be all about the details and reasons you should buy this performance RMM for your Mazda 3, Mazda 6, or CX-5.  All those details can be found on our website, and I invite you to check them out.

What we really want to get across here is this:

First and foremost, we will always do the best we can to take care of you and your car if there is ever an issue or concern with your CorkSport part.  

Second, if you are a driving enthusiast, if you go driving for the sake of just driving, then you need this RMM in your life. It will completely change and improve your driving experience, plain and simple.  

-Barett, CS Engineering

 

Introducing: The CorkSport Performance Polyurethane Exhaust Hanger Kit

The exhaust system on your Mazda is a loved and cherished part of your car’s character and performance.

It emits glorious sounds that keep you entertained and smiling from ear-to-ear, but if you can believe it, is only attached to your Mazda by a few soft rubber hangers.

Yes, your hard-earned stainless steel exhaust is ONLY suspended by small pieces of rubber…

Best replacement for the Mazda CX-5 Exhaust Hanger Kit

Here at CorkSport, we think it’s time that you show your exhaust system some love… it’s time to take the rubber off.

The Mazda CX-5 Exhaust Hanger Kit

We present to you: the CorkSport Performance Polyurethane Exhaust Hanger kit.

The exhaust hanger kit replaces the four rubber exhaust hangers that would otherwise be used to mount and suspend your CorkSport Performance Exhaust System; the two rear hangers on the axle back section and the two mid-pipe hangers.

But why is polyurethane better?

Well there are a few reasons:

  • First, polyurethane is more durable and heat resistant than rubber so the hangers will perform better for a much longer period of time.
  • Second, and most importantly, the polyurethane used in the CorkSport Performance Kit uses a stiffer compound compared to the OE. The polyurethane hangers have 75A durometer stiffness vs the OE rubber at as low as 50A durometer. The increased stiffness helps minimize the movement of the exhaust while still providing the necessary flex between the car chassis and the exhaust system.
Mazda CX-5 Exhaust Hanger Kit with Exhaust

All-together, this means your performance exhaust system for you Mazda 3, Mazda 6, or Mazda CX-5 will not be able to move around under the car during spirited driving such as back roads, auto-crossing, or whatever motorsport event you prefer.

Keeping your exhaust system in place reduces your chance of damaging your beloved Mazda or the exhaust; it’s a win/win.

Link button to CX-5 Mazda Exhaust Hanger Kit

-Barett @ CS

PS: In addition to these hangers, we also carry the following other exhaust hanger options: