Tag: R&D

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CorkSport 2010 Mazdaspeed 3 – The Tireless Worker

CorkSport currently develops parts to support 22 Mazda models and at times one of the trickiest parts of designing parts for all of these cars is finding a car to use during the development process.

Occasionally it can be hard to source a car and find someone who is willing to let you start cutting on their brand new car, which is why it is so great to have our 2010 Mazdaspeed 3 at the shop to use for product development.

Many of you have seen pictures of the CorkSport Mazdaspeed 3 and say how great it looks, but little do you know that it’s a true workhorse.

In the past few months I have seen more parts go on and come back off of this car than I ever would have guessed. Hardly a day goes by when something is not being done to it to further development of our Mazdaspeed 3 line. In the past couple weeks alone it has had three different exhaust combinations on it and at one point even had a TMIC on it for a day while the FMIC piping was still installed but disconnected.

One of the great parts of being an engineer for CorkSport is not spending all day sitting at a desk. I’m able to get out and actually work on a car, put it on the lift, prototype parts, test fit samples, and get some actual real world testing on our new parts. This allows us to develop top of the line parts that have been thoroughly tested in real world environments on a shortened development schedule because we don’t have to develop, send parts out to identified R&D cars, wait for feedback, then tweak the design and start the process all over again. Being able to just walk out into the shop to look at something or install a prototype for testing is great. We can get immediate results so we can get the product out to you, the customer sooner.

We recently released our Front Mount Intercooler Kit for Short Ram Intake and some of you with large power aspirations had questions about the fitment of a larger intercooler. The kit we released with the 24x 6x 3.5″ does not require you to remove the crash bar and in order to accommodate a larger intercooler, removal of the crash bar is necessary. Having our shop car not too far from my desk, I was able to go out and fit a larger intercooler onto the speed 3, prototype some brackets, test and then adjust the design to accommodate the larger intercooler core in just over a month. We now have an option for those of you that want to upgrade your turbo and run a CorkSport FMIC for SRI. The new larger intercooler core is 24x 11x 3” and can support up to 700hp.

Having the car here also means we get to drive it and experience how new parts will act in the real world. We can find out how it handles in stop and go traffic, how comfortable it is on the freeway, and how it looks driving down the road. A couple days this week I was able to drive the car to and from work and I can definitely say that even with all of the performance parts installed, the car is still a great daily driver.

I must say having a car like the CorkSport 2010 Mazdaspeed 3 available to use as a development tool really helps us create the best possible product for CorkSport customers.

Andrew-

Current List of Performance and Accessory Parts on the CorkSport 2010 Mazdaspeed 3

Engine and Drivetrain
CorkSport Short Ram Intake
CorkSport FMIC for SRI Kit
CorkSport Cat Back Exhaust
CorkSport Racepipe
Corksport Motor Mount Inserts
CorkSport Lightweight Crankshaft Pulley
CorkSport Silicone Radiator Hose Set
CorkSport Aluminum Skidplate

Suspension and Wheels
CorkSport Adjustable Rear Swaybar
CorkSport Front Swaybar
CorkSport Lowering Springs
CorkSport Trunk brace set

Interior/Exterior Styling
CorkSport LED Light Kit
CorkSport Stub Antenna
CorkSport License Plate Frame
CorkSport Mud Flaps
J-Spec LED Tail Lights
AutoExe Front Bumper
Advan RZ 19×8.5 wheels
Yokohama S-drive 235/35/19 tires

In Prototype
CorkSport Shifter Base Bushings
CorkSport Front Adjustable End Links
CorkSport Oil Catch Can
CorkSport Camber Plates

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Customer Collaboration Designs Excellence

We say it a lot here at CorkSport, but it’s true, we really enjoy getting our customers involved with the development process and as an engineer at CorkSport, I get to interact with customers on new product ideas and collaborate on their development regularly.

Many of our new product ideas actually come from customer submissions which have been collected and reviewed during our development meetings. Once we have established whether the idea submission has merits and we feel it is a project worth pursuing, it gets added to our project plan and we begin the process of product development.

It’s important for us to keep our customers close to the development process to make sure we don’t lose sight of the original intention of the product or miss an important feature during development that was desired, so once an idea is approved, we reach out to the customers that submitted the idea and determine their interest level in helping CorkSport test the product and discuss getting involved in the development process by providing additional ideas or expressing concerns about the design.

We stay connected with the customer advocate and make sure things are progressing how they feel is best for the product. Once we have a prototype we will find customers who want to help with the testing and validation process to determine if anything needs to be adjusted prior to proceeding to production.

We also make sure to share our new products with the Mazda community through forum interaction. This gives us exposure to a larger audience of customers who may be interested in the product, and because forums can sometimes be brutally honest it really helps us see what may be lacking or needing change.

A good example of this would be our newly redesigned mud flaps for the Mazdaspeed6. We had originally released these using the same mud flaps that we developed for the Mazdaspeed3 but some customers felt they were too hard to install. We then went back and completely redesigned the front mud flaps specifically for the Mazdaspeed6.

I posted pictures of our prototypes on the Mazdaspeed Forum and Mazda6 Club to see if anything needed to be changed before we got ready to release them. During the discussion thread, some comments were made on the length of the front mud flaps and fitment issues that may occur depending in your ride height, so we incorporated a template into the installation instructions that allows customers to trim the mud flaps to their desired length.

Customer collaboration does not end once the part is released either. We like to follow up with customers who purchased our new product releases and get their feedback and have an active knowledgebase that customers can go to for questions and can contribute to with comments and feedback.

It is important for us to make sure that customers are happy with the product and that the installation instructions are clear, concise and easy to follow. If a step is identified that requires additional clarification or could use additional product pictures, we incorporate that feedback into the new version of the instruction sets that go out. This collaboration helps us improve our products and makes us aware of things that may need to be addressed on other projects.

We welcome questions and comments from our customers at any time. If are installing a CorkSport product and have any questions we encourage you to contact us so we can help and if you ever have any suggestions on ways we can improve any of our products please let us know. It is important to us to remain close to the Mazda enthusiasts that have made our company the success it is today.

Andrew-

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What’s Going On! CorkSport Development Update

At CorkSport, we are always looking for ways to improve Mazda Performance through the development of new products. We have multiple projects in various stages of development at all times and as one of the lead engineers here, I am kept busy managing the design, implementation and evolution of many of the products introduced into the CorkSport lineup.

Since I started at CorkSport, I have been involved in the testing and final release of some of the new products in the CorkSport line such as the CorkSport Mazdaspeed 3 Lowering Springs and the CorkSport Stub Antenna and I am currently working several projects that we will be releasing over the next few months. Our customers often say that they want to know more about what’s in store for our new product releases and details about how the development process takes place so today I wanted to fill you in on some of the great things going on behind the scenes here at CorkSport.

One of the products I am particularly excited about is the CorkSport Oil Catch Can we are developing for the Mazdaspeed vehicle line. It aims to help filter out the junk that can end up in your intake manifold. One of the main reasons we wanted to develop this product is because the PCV system in the turbo MZR engine has a bad rap and is not known for performing well. Its purpose is to get rid of the particles and gases in the crankcase that get blown by the piston during compression. It helps filter out these particles to keep them from getting mixed in with your oil and from being dumped into the environment. The problem is that these particles get recycled through your engine and recombusted. They also get caked on your intake valves and intake track. In a normal port injected engine this isn’t as big of a deal because the fuel helps wash the deposits away and keep your valves clean. However on a direct injected engine, as found on the Mazdaspeed vehicles, the fuel is injected right into the cylinder and no longer acts as a cleaning agent for the valves so deposits begin to form. The CorkSport Catch Can will filter out the junk that would end up in your intake manifold and possibly on your valves keeping your intake clean. All that is required is that the can emptied with every oil change.

During testing we had the samples removed from the catch can analyzed. The test results shown below reveal just how much junk is entering your engine.

Another pet project I am working on is the development of a FMIC kit that will work seamlessly with the short ram intake on the Mazdaspeed3 and Mazdaspeed6. We have been running the kit on the CorkSport Mazdaspeed3 with great results and have just completed the design of the piping on the Mazdaspeed6 to begin test fitment of that vehicle.

A product that will be entering the lineup in the near future is the CorkSport Rear Sway Bar for the Mazdaspeed 6. We have a test product installed on a customer’s car and it has been performing quite well. Our customer has seen improved handling, faster cornering speeds, and more traction. With the sway bar being a slightly difficult install, I was sure to take lots of pictures during the install in order to provide our customers complete and thorough instructions to make the process a little easier. And of course if a customer runs into difficulty during the install, they can always call us for help.

Most of the products currently under development have originated from product submissions we have received from all of you. If you ever have any ideas for a new product don’t be afraid to submit it. We have a monthly development meeting to evaluate every product submission we receive, so please let us know what you have been wanting for your Mazda!

Andrew-

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CorkSport Officially Adds the MazdaSpeed Top Mount Intercooler to the Product Line-up

CorkSport is pleased to announce the latest addition to our product line-up, the premium-quality CorkSport Mazdaspeed Top Mount Intercooler (TMIC). The newly engineered TMIC is made from CorkSport’s own custom cast end tanks which are TIG welded to a 3” thick bar and plate core, providing added performance by removing the bottleneck restriction of the stock intercooler and increasing resistance to heat soak by using thicker materials. The cold pipe connection is CNC milled and drilled for a leak proof connection and all bolt holes have been capped off.

CorkSport’s innovative design allows for the reuse of the Mazda OEM plastic shroud leaving your engine bay looking completely stock; however an optional aluminum ring has been made available and can be customized to compliment the finish of any engine bay.

CorkSport Mazdaspeed Top Mount Intercooler

The CorkSport TMIC has been vigorously tested to ensure optimal characteristics. Testing completed on a SuperFlow test bench proved a 46% increase in airflow over the Mazda OEM intercooler. During the testing, the CorkSport TMIC showed an average decrease in pressure across the core by 53% and an increase in overall efficiency of 25% over the stock intercooler.

“After many months of design, testing, and data collection, we are proud to release our highly anticipated CorkSport Top Mount Intercooler”, said Rich Harris, President of CorkSport, “Our TMIC provides solid power gains and is a great value add to the Mazdaspeed 3, MazdaSpeed6 and CX-7 turbo. Pre-sales of the product have shown a strong demand in the marketplace for the newest addition to the CorkSport line”.

The CorkSport Top Mount Intercooler is available now for purchase at www.corksport.com or by phone at (360) 260-CORK. The CorkSport Top Mount Intercooler features full color installation instructions and comes with all the required installation hardware.

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PRESS RELEASE MADNESS: FOUR PRODUCTS; ONE POST!

CorkSport Banjo Bolt 1986-1995 RX-7 & 2004-2011 RX-8

CorkSport Banjo Bolt 1986-1995 RX-7 & 2004-2011 RX-8

The basis behind this part is rather simple. A rotary engine relies on the external oil coolers to keep engine temperatures down. The CorkSport Banjo Bolt is made with an 1/8″ NPT fitting on the end to enable you to install a sensor for either an oil pressure or oil temperature gauge. The idea for this part originated from a customer who didn’t like the look for function of current oil filter adapter plates. Many aftermarket oil gauge adapter plates cause interference with intercooler piping and are an unattractive mess.

Features:
We start with a solid steel 23mm hex bar stock. The ends are turned, tapped, and threaded using a CNC lathe, and the middle is finished with offset oil passages to improve oil flow. Finally, the banjo bolt is run through a deburring process, cleaned in an acid bath, and yellow zinc coated for years of hassle-free use. From us, the end is fitted with an 1/8″ NPT fitting (with plug in case you ever need to remove the gauge sender, or are waiting to buy one) that utilizes a straight-through design to ensure accurate oil readings. The banjo bolt also comes with two (2) copper crush washers to ensure a leakproof seal.

Testing:
The CorkSport Banjo Bolt was designed specifically for the Mazda Rotary engine. We have tested this part to work perfectly with the OEM oil cooler lines as well as our CorkSport brand Stainless Steel Braided Oil Cooler Lines. The bolt installs in minutes with simple hand tools (23mm wrench, socket, & torque wrench) in minutes.

Available Now:
The CorkSport Banjo Bolt is available today at a price that pales in comparison to the level of quality and time invested in the design and precision manufacturing of the product. As with all our CorkSport brand products the Banjo Bolt ships with all the hardware you need for installation, and also includes full color instructions and telephone technical support.

CorkSport Power Series Air Box for the 2010+ Mazda 3 with the CorkSport SRI

CorkSport Power Series Air Box for the 2010+ Mazda 3 with the CorkSport SRI

After the release of our popular Mazdaspeed 3 Air Box, there has been an increased demand for a 2010+ Mazda 3 Cold Air Box. As a result, Corksport is proud to announce the release of our thermally isolating air box for use with the CorkSport Short Ram Intake. The air box mounts to factory locations and limits the ingress of hot underhood air into the intake system of your Mazda 3.

Features:
The CorkSport Power Series Air Box is made from high temperature resistant fiber reinforced plastic (FRP)
that has a full gelcoat on the outside as well as an automotive grade finish on the inside. It is ready for paint
to compliment your engine compartment and styling of your vehicle (or may be left unfinished). The air box features a fully sealed lid with 4 socket head cap screws attaching the lid to the box. The box features a small slit for the MAF sensor wiring to keep it hidden from view. It also includes a mounting hole with bolt to keep your vacuum line up and out of the way for a nice, clean look.

Testing:
Our 2010+ Mazda 3 air box has gone through several design iterations to ensure that it will be an effective and cost efficient way to help decrease intake temperatures and also give your engine bay a stock look. We have observed that our CAB design will decrease temps roughly 30 degrees during highway driving and up to 60 degrees in stop-and-go traffic (decreases heat soak).

Power Series Exhaust for the 2011+ Mazda 2

Power Series Exhaust for the 2011+ Mazda 2

This system was specifically designed for the North American version of the 2 (or Demio). The exhaust will improve vehicle throttle response as well as give your 2 a slightly louder, and deeper tone.

The exhaust installs in about an hour and includes all the necessary hardware to complete the installation. It fits with all existing and future CorkSport brand parts and offers a design and sound that will set your 2 apart from the crowd.

Features:
Our CorkSport Power Series Exhaust is made from 58mm diameter fully TIG welded T304 Stainless Steel, that gives a quality and look that will outlast coated or plated mild steel systems. The kit includes a midpipe with resonator and a muffler which features a 90mm double wall tip. The system also includes a racepipe (cat delete, which is for off-road use only), which can be installed or left off the vehicle. The midpipe slip fit design utilizes a two bolt clamp that allows you to switch between the racepipe and factory catalyst pipe (does require one cut in the factory midpipe).

Testing:
Being the first purchased Mazda 2 in the US, our 2 has been through several design changes and versions of our prototype exhaust. The final product is a result of many months of testing, which delivers a non-overbearing low tone. The 58mm exhaust has been paired with one small resonator up front and a larger muffler in the rear to give it it’s unique sound.

CorkSport Front Swaybar for the 2010-2011+ MazdaSpeed3

CorkSport Front Swaybar for the 2010-2011+ MazdaSpeed3

Due to the popularity of our adjustable rear sway bar, CorkSport is proud to announce the release of our Front Sway Bar for the 2010-2011+ MazdaSpeed 3. This part was specifically designed and tested for the Mazdaspeed 3. The Corksport front sway bar improves handling by stiffening the link between the front wheels. This allows the vehicle to maintain ride height and comfort, while minimizing body roll during cornering.

Features:
To start with, we engineered our bar using a 3 peice design, which allows for greater torsional strength, and smoother travel over one peice designs. The 3 peice design also allows a hollow 1 & 1/8” bar design, which helps maximize stiffness, while minimizing weight. The bar ships fully powdercoated to protect it from the elements, enabling it to maintain it’s torsional rigidity. It also includes Energy Suspension brand polyurethane bushings and zinc plated brackets with grease fittings so there is no need to remove the bar for re-greasing like the stock bar.

Testing:
The bar was designed with the CorkSport rear sway bar in mind. The front sway bar is not position adjustable by design. The increased bar diameter has been engineered to match the middle setting on our rear sway bar. If you prefer more under or over-steer, simply set the rear bar firmer or softer to match your driving style. The front sway bar is 45% stiffer than stock and does not require you to modify your end-links.