Red Baron Speed of Newberg

My Name is Symon Powlison and this is my journey of how I got my Mazdaspeed3 and the Mazda community that became my family. 

Let’s head back in time a bit, I was a broke high school student and I had just bought a 1997 dodge avenger, while my friends had all dabbled with modifying their cars at the time, I had not, but I knew I wanted to. The avenger came with an exhaust that sounded ok and some wheels and that’s about it.

When I showed my new car to my best friend Barett (yes Corksport Barett) and talked about build aspirations that never happened, we decided that we both wanted new stereo and subs, 2007-2008 was the time for loud music and lots of bass lol, “Darude Sandstorm” anyone? 

I had a lot of fun with that car but long story short the car was towed away late in the night for having a flat tire in a parking lot. Now with little to no money and my little avenger was never to be seen again. All is not lost though because those early years with that car started me on a slow trek of building my own “Racecar” later in life it was the catalyst that started it all. 

Fast forward to the year 2012, I’m a bit more established now and I’m getting ready to deploy at the first of the year for 10 months, when my Co-Worker decides to buy a BMW 335i, I made the brash decision to follow suit and I purchased a 2004 Audi S4, my wife was needing a new car anyway so I gave her the Kia Optima I had purchased a few months back. 

Everybody was happy because I got my car and my wife got a brand new Kia! My Audi came with Tien lower springs, a nice fender roll job, and a Magna-flow exhaust. The roar of the V8 through the exhaust was great, it had quick get up and go and it looked amazing in the brilliant red paint. This was my first experience with a “quick” car and I was hooked, but with Audi’s, I had no idea how to even begin to work on it if it had problems, and neither did anybody close to me. This is when I knew this wouldn’t last but I thoroughly enjoyed it when I had it. 

Symon Powlison CorkSport Mazdaspeed3
Symon Powlison

During deployment, I would leave my Audi in the hands of Barett, and return to resume driving bliss with the car, until I left again except this time it would be for nearly 3 years. My wife and I left for Korea in the middle of 2014. My car was out of my possession longer than in my possession and thus while my time away I grew apart from my Audi and wanted something new, different, I wanted a hatchback. 

I always liked the way hatches look, the bodylines, the mildly flared fenders, the base stance of the hatchback drew me in. I spent countless hours looking at every model of hot hatches, tirelessly and sometimes redundantly, maybe I could afford this or maybe I should buy. I decided to call Barett from Korea and told him I was coming home and I wanted to sell the Audi and get something I truly desired. 

He mentioned getting a Mazdaspeed3, I had seen some videos about them but I was rather set on an all-wheel-drive hatch to drive in the snow, but that was dumb because I hate driving in the snow lol. I decided to give the Speed a deep dive look and man I was impressed, not to mention I had an endless resource if I needed any help. 

I was sold, the price was right, the whole car package was right, it checked all my boxes, I wanted a turbo 4cyl with good base stats, something reliable to a degree, and something that I could learn to modify and have help if anything breaks. 

I arrived home in the spring of 2017, and scoured the interwebz and found the speed of my dreams, a velocity red 2013 tech package mazdaspeed3 with 69k on the dash. With what money I had left in savings, a small income, and an Audi for a deposit. I marched down to the dealership and literally, 6 hours later I walked out of there with my dream car. 

Symon Powlison CorkSport Mazdaspeed3
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Funny side note here, when I took the MS3 for a test drive I was by myself, I never drove a 6-speed manual car before and didn’t know how to put the car in reverse, so here I am sitting in somebody’s driveway (huge facepalm) trying to figure out how to put the car in reverse when the homeowner comes out and asks if I need help. I tell him the story he laughs and gives me a push to send me on my way back to the dealer. 

That test drive officially sold me on the car, I can still remember the first time starting that car and the first time I hit 15psi of boost, it was amazing and probably the coolest feeling ever while driving. I couldn’t wait to show my wife, I ripped the speed all the way home, and it was nothing but smiles per gallon. I couldn’t have been happier. I am honored to have such a loving wife who was just as excited for me to have a car I desired so much. This was my very first and only turbo car I’ve ever owned and every time the car plants my back to the seat I can help but grin from ear to ear. 

I kept the car stock for a year on the dot before I started modifying it, if you’re keeping track it’s now April 2018. I purchased all the necessary supporting mods to keep it from going ZZB. I bought an Access port, HPFP Internals, intake, and pro tune and man did that little K04 come alive, a few other supporting mods like exhaust and rear sway bar brought the Mazdaspeed to a different level. 

Symon Powlison CorkSport Mazdaspeed3
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The Speed had no changes for another year or less (early spring 2019), finally, it was time for power mods, big turbo, big FMIC, lots of little bits like injector seals, short shifter, motor mounts, and getting a tune from Purple Drank. The car became a monster, smiles turned to white knuckles gripping the wheel from torque steer, turbo noises for days, and a singing bypass valve that subtly lets you know it’s there on any occasion. 

That kept me satisfied for another year till now, this plan is to do both manifolds, cams, and EWG. *Hurray for race car noises*. The transformation of my Speed over the last 3 years has been a rewarding experience, providing me with knowledge and experience and confidence to be able to tackle any problems or situations previously I would have avoided or paid an overpriced shop to fix.

This is the best part of the community I joined when I bought my speed, all the experiences and knowledge that has been shared with me have been nothing short of amazing and I’m truly grateful for the speed community. My wife and I don’t take a lot of vacations, but the two events that come up in the year that you can’t miss are Mazda events. 

Symon Powlison CorkSport Mazdaspeed3
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I didn’t know that I could miss Idaho as much as I would when I have to leave Papa Keith’s Mazda Takeover event in Boise after a 4-day party. The big bear puts on an amazing event yearly and when it wraps up the withdrawals of it kick in. Those pains are subsided though just two months later when we all get to catch up for CorkSport’s Dyno Day’s! The event that the CorkSport crew puts together is a blast, its high tempo 2-day event that brings our Mazda community together in the Pacific Northwest, I have seen people from British Columbia to Utah come all the way to Vancouver, WA for this event. 

These two trips are something that flows into my DNA and I can’t imagine my life without experiencing them or the people I’ve met along the way. My wife and I look forward to these weekends as I’m sure anyone who has gone to them at least once will, we love spending time with our extended Mazda family and I wouldn’t change it for the world. 

In closing, to say that a car would change my life would be an understatement, but it did and I wouldn’t want it any other way, so if you see the Red Baron Speed of Newberg out and about, come up and say hi and chat for a minute. I hope to see you all at future events, keep hitting that Boost, and stay safe. See you all on the road.

  • Symon

MZR DISI Injector Seals – The Correct Seal for YOUR Speed

Many years ago we helped bring a revolutionary design to the Mazdaspeed community.  Fast forward 4+ years and you’ll find that the CorkSport Tokay Injector Seals are still the best option for your Mazdaspeed.  

Recently, we had a customer ship their stock block engine core to us for a fresh Dankai 2 Built Block.  During the engine core tear-down and inspection, we found a set of CorkSport Injector Seals installed.  We realized this was a great opportunity to share what we found with the community.

When the CorkSport Injector Seals arrive at your door they look like this:

Brand new a fresh of the lathe with all of their beryllium copper brilliance.  After many thousands of miles of use and abuse they look like this:

Now to the untrained eye you may think they look bad, but the truth is they look fantastic!  The visible top of the seal has a small amount of carbon deposits present. This is to be expected because this surface is exposed to the combustion chamber.  Moving to the side of the seal you can see a distinct clean edge and no carbon deposits on the sides of the seal. This distinct clean edge is where the exterior of the seal is designed to seal in the cylinder head.  This is awesome!

Now let’s look at the inside of the used seals:

Again we see carbon deposits, but they are in and only in the expected locations.  Moving up the side of the seal you can see a “shelf” or “step” that is clean. This is the edge that the fuel injector seals against. Beyond that the inside of the seal is clean.

From this inspection we can see that the injector seal was functioning as designed and doing its job effectively.  

So you might be asking…”What is so special about this design?” Well, we wrote a two-part design blog answering that exactly.  We highly suggest spending the 10 minutes to read these.

Injector Seals Design Part 1

Injector Seals Design Part 2

This is exactly why every single CorkSport Dankai Built Long Block includes a set of CS Injector Seals, but if you’re not looking for a built block but still want the assurance of the CS Seals you can check them out right here.  The install of the seal can be a bit tricky sometimes, especially getting dirty injectors out of the cylinder head.  Because of that we’ve developed an injector puller tool that makes the job MUCH easier.  

We hope you enjoyed this quick tech inspection of the injector seals!  Thanks for tuning in with CorkSport Mazda Performance.

-Barett @ CS

Why You Need Injector Seals for your Mazdaspeed, Part 2

This post is part 2 of a 2-part series on the importance of injector seals. If you’re just now discovering this post, be sure to tune in to part 1 before continuing here.

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Like the title says, you need injector seals for your MZR! Here’s why.

When Mazda designs a part, they design it with the “typical” customer and OEM power in mind – not the power hungry, boost craving driver.  Yeah, I’m talking about you and you know it – and we have just the thing to keep you and your MZR in check.  As you add more fuel and more boost, the weakest link is eventually going to give. That link is the OEM injector seals.

Three Reasons You Need Injector Seals For Your Mazdaspeed

  1. Reliability is sacrificed using the OEM seals.
  2. Leaking seals causes loss of power.
  3. Inconsistent performance is caused by leaks.

So, if you are just tuning in to our blog, then shame on you, go read part one like everyone else! With that, let’s dive into the design of the seal and how it works.

We put 500 hard miles on the Speed3 and here are the results.  500 miles may not sound like a lot, but the company owned MS3 does not live the normal life. It spends most of its time on the dyno testing new products pull after pull, may have hit 35psi, and when it does hit the streets, it’s driven by an employee searching for the governor speed.  I think we can all agree that the 500 miles was a fair amount of abuse to put the injector seals. Plus, other sets of seals have been running in alpha testers vehicles for thousands of miles without issue.

Now that we have that covered, let’s talk a bit more about the design of the seal and how it works.

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-

It’s no longer just a washer with one sealing surface – it’s a cup. So it seals in the OEM location AND along the side of the cup. The secret is in the design (which is all thanks to @Tokay444 from MazdaSpeedForums).  The lip at the bottom of the cup is flared just a bit so that it crushes down tight against the cylinder head, and as it crushes down it also crushes outward, pushing against the wall of the port much like an O-ring. If you are having trouble visualizing the flared lip crushing outward then check out the image below. Time to get technical!

FEA-COrkSport-Injector-Seals

Looking at this side view of the seal, you can clearly see that the flared lip is extended further outward than the side of the seal. (Please note that in this FEA, or Finite Element Analysis, the deformation scale factor is 6.5:1, i.e. highly exaggerated). This design is what separates the CorkSport seal from any other seals on the market today. In the FEA the seal is subjected to 3300lbf in the direction of the arrows; 3300lbf is the approximate clamping force of an M8x1.25 torqued to 18ft-lb. The areas in red indicate a displacement of 0.0057 inches, which is just enough to begin yielding (permanently bending) the beryllium copper material. After the 500 miles of use, we had the four seals precision measured using a CMM (Coordinate Measuring Machine). On average, the seals yielded 0.0015 inches confirming our FEA.

Still following?

So what does this mean to you? When you torque down the fuel injector bolt and clamp you are applying approximately 3300lbf to the injector seal. This crushes the seal downward pushing the flared lip outward into the wall for ultimate sealing strength; and we have all the data to prove it! The CorkSport seal works flawlessly, but because of the design they are not reusable like any other crush seal.

So, now that we are done with all the technical stuff let’s take a look at the used seals. First, I would like to remind you what the injector looked like with the OEM crush washer and only 4000 miles.

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Info-Tech-Injector-Fuel

Extremely dirty with an excessive amount of combustion gases blowing by the OEM injector seal. This makes for a very unhappy MZR. Second, in the images you are about to see, the seals have not been cleaned in any way, shape, or form. I pulled these out of the car and immediately took the pictures. Prepare to be WOW’d; I know I was…

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Info-Tech-Injector-Fuel-2

 

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Info-Tech-Injector-Fuel-3

Besides the clean injector body, there is a more subtle detail that needs to be pointed out. If you look at the very edge of the flared lip on the seal you will notice that the black soot does not go all the way to the edge. This further confirms that the seals are working the way Brock (@Tokay444 on MSF) had envisioned them and we can also see this “clean ring” in the cylinder head below.

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Info-Tech-Injector-Fuel-Inside-Intake-Manifold

In the image below you will notice that the seal is dirty on the inside, but that’s okay – that happens by design. The “shelf” that you see midway up on the inside of the seal seals against the injector body instead of in the OEM location further down around the injector nozzle. This change in sealing location allows the flared edge to deflect how it needs.

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Seal-Dirty

If I haven’t convinced you yet why you need injector seals for your Speed3 then you’re hopeless…you should go get a Civic or something else that’s slow…

Injector-Seals-Mazdaspeed-MZR-Engine-Tokay-Full-Injector

Between our results and the reviews given to us from our alpha testers we have great confidence in the seals and you should too! Keep an eye out for these to be released very soon! Zoom – Zoom! -Barett, CS Engineering