CorkSport BIG Turbo

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 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 turbos 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 more 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.

 

Kill The Nannies

Nannies. One thing we have discovered while racing our Mazda 3 is that the OEM safety systems in the newest generation of Mazda 3 work well, too well in fact for racing.

Each year, new safety features are added by Mazda which make the cars safer and reduces the risk of collisions. This is great for day to day driving and commuting, but it presents a problem if you plan to take your car to the track to race it.

The OEM system in the car really frowns on lifting a rear tire off the ground, or when you get wheel spin accelerating out of a slow speed corner. They design the cars against these things happening for safety purposes (understandably). However, Mazda does give you a button on your dash to turn off the traction control. This gets us racers around the limitations to a certain degree.

Let me explain:

When you disengage traction control, the system which measures yaw/pitch and ensures your car has all the wheels on the ground is actually still working, even with the button off. What the button does essentially is give you a sort of leash with more leeway, until the computer thinks you have gone too far of course, then it will kick in traction control again.

So, how do we get past these nanny systems so we can push our cars for maximum performance?

Can you simply unplug the computer which controls the this? I wish it were that simple, but you cannot. The systems in the car are all tied to each other, and the car may not start, it may not run safely, or it may run in a limp mode. A good example of this in our 2015 Mazda3 is: if you unplug the rear view mirror the car won’t start. The ABS is also controlled by the same unit, and this is very handy to have on the track.  The ABS is very good in the Mazda3 by the way, so I recommend you keep it.

The solution we’ve come up with at CorkSport is pretty simple: Leave the computer plugged in and turn it over.

That’s it, simple, nothing else is required. What happens when you turn the computer upside down is the computer loses its physical reference point, so it defaults by turning off the stability control and nannies, but most-importantly, the ABS still functions.

A big word of caution: The computer which controls the nannies also runs the airbags. If you race your car on the track, the airbags will have been removed from your car already. DO NOT drive your airbag-equipped car with the module flipped over.

The reason this solution works for the track is that our Mazda 3 race car has additional safety equipment installed, with the 6-point harness and halo seat, along with the rest of the driver’s safety gear, that keep you from injury in the event of any wrecks.

FYI: When using this “hack”, your Mazda 3 dashboard will light up like a Christmas tree from all of the warnings; but that is a small price to pay for the improved performance while racing.

–Derrick

DISCLAIMER: This modification is for racing purposes ONLY. Doing so will render many of your car’s safety systems ineffective. Installing other safety systems after this modification is essential.

 

2018 Mazda 3 CBR – Transmission Modes Comparison

If you didn’t know already, CorkSport recently bought a brand new 2018 Mazda 3 Hatchback Touring Modelwith an automatic transmission.

Yes, I know, a performance aftermarket parts company has an automatic; I’m right there with you, but there’s a good reason for it.  CorkSport has a couple Mazda3 6-Speed Manuals and a couple manual and automatic Mazda 6’s, but no automatic Mazda 3; so it made sense to add that to the garage, especially with the many new performance parts we have in the pipe line.  Check those out here.

Now back to the CorkSport’s new 2018 Mazda 3.

The 6-speed automatic comes equipped with three transmission control modes; Standard (default), Sport, and Manual (aka manumatic).

We became curious about how those three modes affected the driving experience, specifically the shift points. I believe we all understand how the Manual control mode works, as it provides nearly 100% control of the shift points, so for the comparison I am going to focus on the differences between the Standard and Sport modes since those are controlled by the ECU.  

Driving the car on the street, you can easily feel the difference between the Standard and Sport modes of the Mazda3.

The Standard mode feels soft, relaxed, and maybe even lazy between shifts. It seems to default to the highest gear (lowest engine RPM) possible in every driving situation. This is great for fuel economy, but disappointing for smiles-per-gallon.  Push the Sport toggle, and the car comes alive.  The engine pulls through the RPM range longer for each gear and seems more eager to accelerate with the slightest throttle input. MUCH better.

The Butt Dyno is great and all, but it’s subjective, so we decided to strap the car down on the dyno to see what is happening; what exactly is changing between the Standard and Sport modes with the CorkSport 2018 Mazda3.

On the dyno, things become much clearer, but first, we had to set up the dyno to provide us with useful information. Typically we are testing wheel Torque and Horsepower, not shift points. It was interesting to play with the various parameters the dyno has available to find a readout that would convey the shift points and the effort the car was exerting. Check out the graph below; this is not your typical dyno plot.

With this dyno plot we quickly see that is much different than the typical readout.  I’m going to break it down, so it’s clear and easy for you to understand what is going on.

Description: Standard Mode = Red, Sport Mode = Green

The horizontal axis is our independent variable in the test. This is the variable/parameter we can control directly in the test. Since we are trying to understand the difference in shift points between the Standard and Sport modes, Road Speed was the logical choice. To be consistent, the throttle input percent for both Standard and Sport modes was held constant throughout the test runs.

The two vertical axis’s are the dependent variables in the test; these are the parameters that depend on engine RPM. On the right side of the dyno plot, we have engine RPM; this is represented by the lines with dots. On the left side of the dyno plot, we have tractive effort, which is essentially the amount of force the tires are applying to the road surface.

Looking at the two graphs, it’s clear that the Sport mode shift points and tractive effort are much different than Standard mode. This is interesting because we can now visualize what we were feeling while driving the Mazda 3 Hatchback on the street.

In Sport mode, the car carries through the engine RPM longer, and the resulting RPM after each shift is also higher.  Because each gear is carried to a higher RPM the resulting power is much greater, which is shown with the tractive effort plots.

Finishing statement: Sport mode significantly changes the way the car drives and responds. If you are looking for some fun out in the curves, don’t be shy, hit that Sport toggle and let the Mazda do what it was designed to do best.

Happy driving!

-Barett @ CS

CorkSport Mazdaspeed 6 Short Shift Plate

It is back from the dead! CorkSport is happy to announce the return of the Mazdaspeed 6/MPS 6 shift plate. We took our original design and adjusted it based on feedback from customers who owned the original to bring you a new and improved product.

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CorkSport’s Mazdaspeed 6 Short Shift Plate has been designed to provide a 33% reduction in shift throw. The unique design of our shift plate provides maximum benefit to Mazdaspeed 6 drivers by changing the geometry at the shifter end to remove the feeling of synchros where it is most noticeable – in gears one and two. The shift plate bolts directly to the car, eliminating the need to bolt on to the factory or an aftermarket counterweight.

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It’s Almost Here: the New CorkSport Front Lip for Gen2 MS3

This may seem long overdue, but let me explain …

Here at CorkSport we listen to all of our awesome customers and take great care on how we plan our projects for product development. A well-fitted front lip specifically designed for the Mazdaspeed3 has understandably been a very frequent request. There is a lot that goes into producing a great product, especially a tight-fitting front lip. Long story short: We wanted to get all of our ducks in a row before we attempted to execute a custom Mazdaspeed3 product you all would love.

Continue reading “It’s Almost Here: the New CorkSport Front Lip for Gen2 MS3”