Why Innovate??

At CorkSport we do so much testing in our R&D process that we sometimes forget that many others might not do the same. Over 6 years ago, we started producing a part that no one else offered. The stock turbo inlet pipe on the 2.3L DISI engine that goes from the intake to the turbo is a restrictive plastic pipe that snakes its way between the battery and the engine.

Stock Mazdaspeed 3 Turbo inlet pipe
Just looking at this pipe you can see the restrictions.

Our original design was to build a mandrel bent pipe version to give the air a good chance of flowing better than the factory part. After building and testing the piece we found out that we were right. The factory turbo inlet pipe flows 486.4CFM (cubic feet per minute) at 28″. Those numbers are not fantastic, but still good enough to get some decent power out of the stock engine. Upon testing our CorkSport Turbo Inlet Pipe, we found that it flowed significantly more; 557.5CFM to be exact. That is a 14.6% improvement in flow!!

CorkSport Turbo Inlet Pipe Mazdaspeed 3 Mazdaspeed 6 CX7

After the release of our part, there were many debates about metal vs. silicone for this part and if you’ll recall, we discussed it in a previous blog post Here and noticed no discernible differences between metal, silicone or plastic. What made the silicone attractive was that it was easier to make and you could make almost any shape you wanted. However, if you don’t have tight control over the shape of silicone you can actually lose flow. With those thoughts in our head, we decided to conduct a test to make sure we were providing the best possible solution for our customers that we knew how to build.

Competitors Turbo Inlet Pipe

With a silicone turbo inlet pipe in hand we tested it with the same methods, we assumed it would be better than the stock piece but what we didn’t know was how much better. After running the Brand X on the test bench we came up with a flow of 509.3CFM. With the smashed design and fewer smooth surfaces, the silicone delivered only a 4.7% increase over the stock piece and 9.4% less than our metal design.

We have sold literally thousands of intakes for Mazdaspeeds, we know there are other brands using marketing similar to our “Power Series” but we have been innovating the Mazda intake market for years.

Just a few of the CorkSport firsts:

  • We were the first to recognize the importance of the turbo inlet pipe in intake design for the MZR DISI to the point of selling an intake that included this component. Our best selling MZR DISI Power Series intakes have been selling for nearly 6 years with the inlet pipe.
  • Our intakes have had color configurable filters, MAF’s, and silicone for years. We were the first to offer this level of customization in the market.
  • We were the first to offer a convertible Short Ram/Cold Air intake.

We at CorkSport want to thank you for supporting our innovation, your support allows us to continue to create new products that will once again elevate the market.

Marketing is very important but we never want to stop there, at CorkSport, we design products we would want on our cars and know that once you see the difference you’ll want them on yours as well. We won’t be stopping with this design though, for those of you that really want to push the envelope we have some fun in store for you this year. We are committed to bringing more intake options this year, and even more CFM’s for those of you that need or want it.

Add Power and Get Better Gas Mileage

When most people think about purchasing an intake, they want it for the performance increases. While an intake is probably the best bang-for-the-buck modification you can make to add power and torque to your Mazda, there is another huge, but often overlooked benefit which is the improved gas mileage.

How is that possible?

The CorkSport intake uses a conical dry flow air filter with 3” outlet that is much less restrictive than the factory filter. This directly translates to better gas mileage. We have also calibrated our precision machined MAF housings and intakes to exacting tolerances and have designed them to work better and more efficiently than the factory intake system.

Where’s the proof?

We were beginning to get feedback from customers stating that they were seeing improvements in their gas mileage with the addition of the intake.

I have a brand new 2012 MS3 that is stock apart from the intake. With this new intake I have seen a my average mpg for the last 12,000 miles of normal break in driving go from 28.4 to 31 miles per gallon while now driving in a much more aggressive manner during the last 1,000 miles. I am thoroughly impressed and I hope that this information can be of use to your company and other customers. – Alex B.

To be sure we needed to control the test conditions and make our own conclusions.

After testing the Skyactiv CX-5 with the factory intake system, we showed an average of 34.0 MPG. After adding the CorkSport Short Ram intake, we have been showing 38.5 MPG average. This is a 13% increase in fuel mileage improvement just by the simple addition of intake system.

We then went a step further and did extensive in town gas mileage testing. Though the results were not as impressive, they were still substantial. The baseline with the stock intake was 29.3mpg and improved to 31.2 with the CorkSport Short Ram Intake. This is a 6.5% improvement in fuel mileage.

Of course the CX-5 SkyActiv was designed with fuel mileage in mind so getting great MPG’s in this car was not surprising. This is when we decided to take our testing to the next level and see what could be achieved on the Mazdaspeed3.

As it turns out, the Mazdaspeed3 showed similar improvements in gas mileage in the city, but significantly less on the highway. We had a 6.1% improvement in city driving and 4.4% Improvement on the highway with a peak of 33.2mpg with the CorkSport intake installed.

Some customers have seen additional increases, but the results are generally subject to how a person drives. Remember with that increase in torque and horsepower you will be more tempted to have a heavier right foot too.

What’s the Payoff?

With gas prices yo-yoing over the last couple years too, at some points, topping 4.00 a gallon here in the pacific northwest, we estimate that the intake will be able to pay for itself in around 13,000-16,000 miles. With a national average of around 15,000 miles driven per year, you can expect your intake purchase to pay off quickly and then start getting money back in your pocket from the fuel savings.

Not only does less gas mean more money in your pocket, but fewer emissions as well, so you can tell all your environmentalist friends that you are doing your part!

To recap, better mpg, more money in your pocket and you a decrease in your carbon foot print. This all sounds good to me.


Avoiding Clamp Failure Modes

As CorkSport works through R&D on any new part we are developing, we always take the time to consider possible failure modes. This ensures the final product has been thoroughly thought out and developed to avoid as many potential failure scenarios as possible.

Failure modes can come in many different forms. There are failure modes brought on by the product that have to be considered, failure modes brought on by assembly and packaging to consider, and failure modes brought about by the installation of the product. Often a failure mode can be a simple issue that may seem trivial until you sit back and consider the potential consequences. For that reason, clamp placement is a critical issue that can be easily overlooked during installation.

The Common Cause of Clamp Failures

When a part is installed that requires clamps, it is easy to consider only the aesthetics of the part. The initial reaction is to want the clamps to be even and silicone to be on properly, but there are a number of other potential hazards that need to be addressed when installing clamps.

The motor itself rocks back and forth which is particularly noticeable on a Mazda where the motor rocks a lot. Because the motor rocks but the engine bay does not, the clamps on your installed parts may move around and come into contact with other parts of the engine bay.

Notice the picture above. Everything looks good until you look closer. The clamp is actually touching the radiator hose which can be a potential failure point with the part. By simply rotating the clamp slightly so the bolt does not come into contact with the radiator hose, you can avoid the contact point and a possible problem with your vehicle.

Clamp placement is critically important with a front mount intercooler install because the clamps have the potential to contact a lot of parts in the engine bay and other pipes. When it comes to intakes, it is also very important to consider clamp placement because they are much closer to critical wiring. Simply flipping the orientation of the clamp can mean the difference between worn plastic and wiring harnesses or trouble free operation for years to come.

Avoiding Clamp Failures

Using the picture below as an example, you can see that the clamp fits well and doesn’t touch anything, but imagine if it was tightened into the stationary object. When it moves back and forth it would eventually rub through the tape and shielding and contact the wires inside. By being aware of this, we can position the clamp so it will never contact. This is something easy to do while you are installing the part, but can be a much bigger headache down the road if it is not considered upfront.

Below is another example of a clamp that is not ideally positioned. We actually have the opposite scenario here to the last example. The clamp is on a pipe that is hard mounted to the frame, while the other pipe is attached to the motor and moves. This will cause the clamp and the pipe to contact and wear against each other over time. Although both are metal, the clamp will eventually work its way through the aluminum pipe and cause a vacuum and boost leak. This means a poor running car and loss of power.

Take Time to Consider Clamp Placement During Install

Take care during your installation and avoid potential pitfalls down the road. By maintaining good clamp placement, not only will you avoid scratching the pipes, but you can avoid other potentially serious issues like boost leaks and unintentional contact with other parts in your engine bay. So remember, always keep your car safe, beautiful, and protected by maintaining good clamp placement.


Product Release! CorkSport Mazda CX-7 Airbox

We know CX-7 owners do not get a lot of attention from Mazda aftermarket performance companies and can often times be overlooked when it comes to performance parts that would otherwise be considered a standard offering for DISI engine Mazda vehicles.

With that said, CorkSport is happy to provide a little love for the CX-7 family with the release of the all new CorkSport Mazda CX-7 Air Box.

Designed specifically for the Mazda CX7, the CorkSport CX-7 Air Box for CorkSport SRI provides protection from the hot underhood air of the engine bay while adding additional access to ambient air temperatures, resulting in greatly reduced temperatures in and around your SRI for less heat soak and more power.

The CorkSport Mazda CX7 Cold Air Box for CorkSport SRI connects to the air induction scoop and can be further modified with an additional opening that can be connected to piping leading to the fenderwell.

The CX-7 Air Box is easy to install allowing customers to quickly upgrade their SRI and get the added advantage that comes with a CAI without the pressure drops inherent to longer intake piping.

For more information or to purchase today, please visit our online catalog at www.corksport.com

Product Release! CorkSport SkyActiv Short Ram Intake

CorkSport began development of the new SkyActiv intake as soon as the technology was made available in the United States and today is happy to be the first Mazda aftermarket performance company to add a short ram intake for the 2012+ SkyActiv Mazda 3 and 2013+ Mazda CX-5 to its catalog of Mazda performance parts.

Engineered with exacting tolerances, the CorkSport Mazda SkyActiv Intake includes our precision machined MAF housing made from billet aluminum, durable dry flow air filter and custom reinforced silicone connector. In initial testing on the SkyActiv Mazda CX5, the CorkSport SkyActiv Short Ram Intake netted peak gains of +5 HP and +6 lb torque.

“Sales for Mazda’s new SkyActiv product line-up have shown tremendous potential and we have had several product requests for a SkyActiv intake,“ said Rich Harris, President of CorkSport Mazda Performance, “Our engineering staff really stepped up to the plate to get our new SkyActiv intake to market quickly in order to fully support the Mazda community.”

CorkSport has already confirmed the fitment of the single exit Mazda 3 exhaust for the SkyActiv Mazda 3 and made it available to the public and is happy to be able to add a second performance offering designed for the SkyActiv technologies developed by Mazda to increase fuel efficiency and engine output.

As with all CorkSport products, the SkyActiv Short Ram Intake comes with a two year limited warranty, full color installation instructions and CorkSport service and support. For added support, this kit also has a complete installation video.

The new addition to the CorkSport catalog is priced at $179.00. The CX-5 SkyActiv intake can be purchased separately in our newly added CorkSport CX5 catalog and the Mazda 3 SkyActiv Intake can be purchased as an option that has been added to the CorkSport Power Series 2.0 Liter Mazda 3 intake.