Ask the Engineer at CorkSport

[CorkSport]

I wanted to start this thread for all of you out there that have questions related to my job. I work on Product development here at CorkSport. I was hoping I could get some ideas on helping the community out by writing technical articles or answering questions.

We also like to get customers involved in development so topics can always turn into products down the line and you could help in the production process.

I will try to monitor this thread on a daily basis so go ahead and ask questions.

Brydon@CorkSport

[superskaterxes]

do you guys have a thermal image camera? it would be really cool if you could do some heat analysis with your cold air box with and without, and temps over different parts of your FMIC!!!!

[CorkSport]

Originally Posted by superskaterxes do you guys have a thermal image camera? it would be really cool if you could do some heat analysis with your cold air box with and without, and temps over different parts of your FMIC!!!!

No thermal imaging camera. Although that is an interesting idea. I have a temp gun, wouldn't get a broad picture like the thermal camera but it would give an idea temp differences. It would also be nice to see the difference between that and the cold air setups. I'm going to guess there is not a lot of difference.

Great idea though.

Originally Posted by MS309 Why did you guys decide to stick with 3" TMIC instead of 3.25" ? Besides being able to use the stock shroud, any other advantages over your competitors ? Sent from my iPhone using Tapatalk

Originally Posted by silvapain Airflow above and below the intercooler. Tapadatass

This answer is exactly correct. If you squeeze out the air there is no benefit to a larger core. Flow through the IC might be better but cooling is all but lost.

[MS309]

Why did you guys decide to stick with 3" TMIC instead of 3.25" ? Besides being able to use the stock shroud, any other advantages over your competitors ?


Sent from my iPhone using Tapatalk

[silvapain]

Originally Posted by MS309 Why did you guys decide to stick with 3" TMIC instead of 3.25" ? Besides being able to use the stock shroud, any other advantages over your competitors ? Sent from my iPhone using Tapatalk

Airflow above and below the intercooler.


Tapadatass

[helmetface]

Originally Posted by silvapain Airflow above and below the intercooler. Tapadatass

The Beard haz spoken

[KILLER_VIZ]

It is good to see companies like yours stepping up and coming to source for ideas. I personally would like to see a 3.5- 4" exhaust so I could make babies and old people shit them selves. lol

[CorkSport]

Originally Posted by KILLER_VIZ It is good to see companies like yours stepping up and coming to source for ideas. I personally would like to see a 3.5- 4" exhaust so I could make babies and old people shit them selves. lol

We really do use a lot of customer ideas. If you want it, submit it. We review all submissions and develop them. Sometimes the idea is not right for us right now but eventually we try to get to most of them.

There would be a better benefit to a 4" downpipe/racepipe. More power for those larger turbo guys with little increase in sound. But if you just want it loud then that is another story.

Originally Posted by Sid3wayS MAKE A MANI THAT HAS EWG AND PREFERABLY FITS WITHOUT MODIFICATION.

An exhaust manifold that is scan to cad off the original manifold for flange locations? Design all the runners to flow better and equal, checked with a 3d print, and then cast in 347SS for strength, color and long lasting? Add a popular EWG option and call it a day?

I will keep this in mind.

The idea to make a intake manifold has been suggested also. I'm not sure what peole would want for that. Cast, larger plenum, even flow? I'm always open to suggestions for what exactly people want.

[Sid3wayS]

Originally Posted by Brydon[MENTION=130 CorkSport;1496067] An exhaust manifold that is scan to cad off the original manifold for flange locations? Design all the runners to flow better and equal, checked with a 3d print, and then cast in 347SS for strength, color and long lasting? Add a popular EWG option and call it a day? I will keep this in mind.

I just had an accident in the front of my pants.
Ballpark of when this idea might be offered to the public? And do not be as vague as soon lol

[Sid3wayS]

MAKE A MANI THAT HAS EWG AND PREFERABLY FITS WITHOUT MODIFICATION.

[Easter Bunny]

How much wood would a woodchuck chuck if a woodchuck could chuck wood?


























Sorry but you didn't specify car related questions

[TiGraySpeed6]

c'mon now, everybody know that a woodchuck would chuck all the wood he could if a woodchuck could chuck wood.

[SofaKingAwesome]

Can you get us noodz of Gwynne?

[IMASA]

Why didn't you guys make the 4pt brace 1 solid, welded piece vs 4 bars bolted to connectors?

[CorkSport]

Originally Posted by IMASA Why didn't you guys make the 4pt brace 1 solid, welded piece vs 4 bars bolted to connectors?

Are you talking the one in the car or under the car. I started to respond but then I thought you might be talking something different. I thought you meant the one under the car. The factory is not as perfect as you would think. There are slight variations in the distances of the subframe to the bolt locations. 4 pieces made it easier to be sure it fits everyone’s car. With cast ends and walled bars it is quite strong.

[IMASA]

Originally Posted by Brydon[MENTION=130 CorkSport;1496139]Are you talking the one in the car or under the car. I started to respond but then I thought you might be talking something different. I thought you meant the one under the car. The factory is not as perfect as you would think. There are slight variations in the distances of the subframe to the bolt locations. 4 pieces made it easier to be sure it fits everyone’s car. With cast ends and walled bars it is quite strong.

Thanks for the response, yes I was refering to the one under the car.

[TiGraySpeed6]

There has been much talk of larger throttle body...

Might not be worth the effort due to pricing, but certainly fits your request for interesting ideas

Lets talk about Bigger Throttle Bodies

[silvapain]

For an IM, balanced flow is the top priority. Higher overall flow second. And flow test both before and after with the TB in place.


Tapadatass

[CorkSport]

Originally Posted by TiGraySpeed6 There has been much talk of larger throttle body... Might not be worth the effort due to pricing, but certainly fits your request for interesting ideas Lets talk about Bigger Throttle Bodies

I will have to have a glass of beer and sit down later and read that whole thread. Looks interesting. Anyone ever though about a roller throttle body? They generally have better idle quality and better flow at higher load.

Originally Posted by silvapain For an IM, balanced flow is the top priority. Higher overall flow second. And flow test both before and after with the TB in place. Tapadatass

I would think that would all be a must. Should be easy to test this in solidworks before casting it.

Originally Posted by Seatime3 Gwynne is Hot!! that said... Intake manifold would be great, yes even flow, higher flowing, and accepting of a larger throttle body. No one else makes this yet Brydon!! Make our dreams come true!!

Find me more hours in the day and I will get started right away.

Originally Posted by SofaKingAwesome Can you get us noodz of Gwynne?

Somethings in this world are impossible with current technology.

Originally Posted by Sid3wayS I just had an accident in the front of my pants. Ballpark of when this idea might be offered to the public? And do not be as vague as soon lol

Did I say we were developing this?

[SRTCE142]

Originally Posted by Brydon[MENTION=130 CorkSport;1496153]I will have to have a glass of beer and sit down later and read that whole thread. Looks interesting. Anyone ever though about a roller throttle body? They generally have better idle quality and better flow at higher load.

i'd never run one of these. we used them for a couple years in the FSAE competition and always had problems with them sticking WOT.

[DiGi Faggot]

At any rate, I second the skid plate. I would really like an aluminum or otherwise metal skid plate that bolts to the front bumper. (MS6)

I also think it'd be very awesome to come up with a nice vented hood that perhaps has a big vent over the intercooler? (MS6/MS3)

I know the MS6 has only been around for a few years and theres less and less of us as time goes on. But if you could find the ability/time to R&D I think some of us would buy these.

Originally Posted by Brydon[MENTION=130 CorkSport;1496153] Somethings in this world are impossible with current technology.

I wont be a creeper and tell you how. But this is totally possible with current technology. Costs maybe 50$.

[Seatime3]

Gwynne is Hot!!
that said...

Intake manifold would be great, yes even flow, higher flowing, and accepting of a larger throttle body. No one else makes this yet Brydon!! Make our dreams come true!!

[Sid3wayS]

No but if you and your company were smart you would have already been working on it and finishing it soon so that you could corner the market which is in high demand right now. Even thou I dont have a single thing from CS I do like the way your compny does things and offers a vast array of stuff for this platform. But Im SURE another company might pick up the slack and already make one if not.

On to more relevent things thou, the coil overs you guys are going to be offering, are they going to be fully adjustable. And by that I might height and stiffness?

[CorkSport]

Originally Posted by Sid3wayS No but if you and your company were smart you would have already been working on it and finishing it soon so that you could corner the market which is in high demand right now. Even thou I dont have a single thing from CS I do like the way your compny does things and offers a vast array of stuff for this platform. But Im SURE another company might pick up the slack and already make one if not. On to more relevent things thou, the coil overs you guys are going to be offering, are they going to be fully adjustable. And by that I might height and stiffness?

I like to wait till we are closer to release before committing to anything we are working on. I hope you understand.

The coilovers are indeed fully adjustable. Height and dampening. We are even releasing the information on the rebound and compression which is sometimes nice for customers to see. The fronts are inverted 45mm with helper springs, camber adjustment, etc (complete front setup) The rears, since it's multilink, are adjustable height, dampening and progressive springs. The bodies of the rear shocks are also adjustable height to optimize performance for people that want and kind of height.

[Sid3wayS]

Originally Posted by Brydon[MENTION=130 CorkSport;1496246]I like to wait till we are closer to release before committing to anything we are working on. I hope you understand. The coilovers are indeed fully adjustable. Height and dampening. We are even releasing the information on the rebound and compression which is sometimes nice for customers to see. The fronts are inverted 45mm with helper springs, camber adjustment, etc (complete front setup) The rears, since it's multilink, are adjustable height, dampening and progressive springs. The bodies of the rear shocks are also adjustable height to optimize performance for people that want and kind of height.

Haha fully I was just tryn to push some buttons and see if I could get you to mess up and say something lol

Thats real good to hear about the coilovers, means they are performance oriented and not just something to slam your car and make it look kool. Might be adding CS to my list afterall then.

[CorkSport]

Originally Posted by Sid3wayS Haha fully I was just tryn to push some buttons and see if I could get you to mess up and say something lol Thats real good to hear about the coilovers, means they are performance oriented and not just something to slam your car and make it look kool. Might be adding CS to my list afterall then.

Trust me, these are not something you would find on ebay for slamming your car. They are more like KW/Mazdaspeed quality with more options like camber plates.

[Vansquish]

Originally Posted by Brydon[MENTION=130 CorkSport;1496283]Trust me, these are not something you would find on ebay for slamming your car. They are more like KW/Mazdaspeed quality with more options like camber plates.

Are you going to offer a set for us (slightly) unloved MS6ers as well?

[Erich]

You might want to consider some changes to the design of your tow hook plate. Everything lines up nicely once it is on the car, but getting it on and lined up properly is a huge pain in the ass. A tow hook plate shouldn't take more than 5-10 minutes to install, and yours takes a great deal longer than that. Reverse threaded with two different setting nuts (which should probably have nylon rings to keep them from spinning once they are set) not good. Also, the smooth plug the plate mounts to should really be slotted for a screw driver as it is likely it will have to go on and off more than once while getting the nut properly positioned.

[kritz]

I'll chime in on the coil overs, they are really aggressively valved and sprung truly track worthy.

@Sid3wayS

[dexter_5000]

can you give us a list of those parts in development?

[06Speed6]

Ms6 engine skid plate
Intake manifold
oil cooler adapter with integrated adjustable temp thermostat for a external oil cooler
liquid air intercooler
vvt upgrade using cores
tb coolant bypass hose
Oil cooler bypass hose
Cheaper ms6 front engine mount
Cams
dual cdfp bracket
Ms6 exhaust that doesnt rattle like a mfer
High flow crankcase breather

Prolly some other stuff that I am forgetting

[TiGraySpeed6]

showing interest for another VVT upgrade...

I, and I suspect more than a few others, still need to replace the original.

[breakfstincluded]

VVT

[TiGraySpeed6]

Any chance we could discuss the engineering involved in quality welds / welding technique?

I hate to see high quality engineering and product development work, which CS is well known for, destroyed by low quality construction, which seems to be the topic of many posts about CS these days...

[blownhead]

Originally Posted by TiGraySpeed6 Any chance we could discuss the engineering involved in quality welds / welding technique? I hate to see high quality engineering and product development work, which CS is well known for, destroyed by low quality construction, which seems to be the topic of many posts about CS these days...

That is the risk they accept when they outsource a product.... i have noticed this on several items ... they still perform as advetised but the tolerances are usually a tad off

[Jarods7920]

What is your background as a product development person at Corksport? What is your degree, experience, etc..

[CorkSport]

Originally Posted by Jarods7920 What is your background as a product development person at Corksport? What is your degree, experience, etc..

3 years experience in Automotive as a tech when I put myself through college. Bachelors’ degree in Electrical engineering and physics. After college, almost 7 years in professional engineering working on design improvements and testing before CorkSport. But I'm not the only engineer in the building.

Lots of hobby cars from muscle cars to present day for non professional experience.

Originally Posted by Erich No comments on my post? Can't really comment on much as far as CS goes as the tow plate is the first CS product I have purchased, but typically if engineers for a company can't get the simple stuff correct I have a hard time trusting the more complex stuff. Which is too bad, because the coil overs sound promising.

Missed it sorry about that. The best idea I thought of was to put square cut-out to put a 3/8 extension in so you could easily tighten it before installing the plate. There is not much profit on these so the extra machining cost was cut out. I might reevaluate this product now though. That is a good idea. Like in every market, unfortunately, most decisions come down to cost.

Originally Posted by dexter_5000 can you give us a list of those parts in development?

Can't do it, sorry. Some we do leak and some we hold back. I hope you understand why.

Originally Posted by 06Speed6 Ms6 engine skid plate That might actually make the cut soon. Intake manifold This interests me as well but I need to clear some other projects off my plate to put a lot of time into this. oil cooler adapter with integrated adjustable temp thermostat for a external oil cooler Thought about this but no one has submitted a product submission for it yet so I didn't move forward. liquid air intercooler We haven’t found a huge interest in this so I'm not sure if there is any money in developing a kit. I guess if a hundred people came in and demanded it then we might talk. vvt upgrade using cores Interesting idea. That might be worth it. I hear these fail often. tb coolant bypass hose You mean an extruded hose bypass? I suppose that would be easy. I thought most people just made the stock stuff work? Oil cooler bypass hose That would be part of a oil cooler kit if we did it. Cheaper ms6 front engine mount Rear? Dogbone? Your wish is on my mind. Cams Why does no one make cams for these cars. The HPFP lobes shouldn't pose that much of an issue. The only issue I see is timing with the DI. Since overlap and fuel timing are difficult. But I see no reason for not have more lift and a slight duration increase while leaving overlap similar? dual cdfp bracket Meaning dual HPFP? At that point you would almost need a larger supply pump and larger lines. A1000? Ms6 exhaust that doesn’t rattle like a mfer Sound or hitting stuff? High flow crankcase breather Blame the factory for that. Getting another option is problematic in that space. Prolly some other stuff that I am forgetting

Originally Posted by TiGraySpeed6 showing interest for another VVT upgrade... I, and I suspect more than a few others, still need to replace the original.

I haven't looked into this much. What is the failing point? Has anyone figured out the issue? Does anyone have a failed one I can dissect?

Originally Posted by SRTCE142 I’d never run one of these. we used them for a couple years in the FSAE competition and always had problems with them sticking WOT.

That shouldn't be an issue with DBW and how the TBs are on the MS3. My though would be to test a 70mm one. The big issue I see is releasing a part that requires lots of tuning changes. That would be problematic.

Originally Posted by TiGraySpeed6 Any chance we could discuss the engineering involved in quality welds / welding technique? I hate to see high quality engineering and product development work, which CS is well known for, destroyed by low quality construction, which seems to be the topic of many posts about CS these days...

There is a chance. My big goal this year is too increase QA to a point where this is not an issue. 90% of Japanese companies went out of business trying to make parts that were double or triple the price that we pay. Quality was never an issue but having customers seemed to be a problem.

Originally Posted by blownhead That is the risk they accept when they outsource a product.... i have noticed this on several items ... they still perform as advertised but the tolerances are usually a tad off

Unfortunately, in some ways you are exactly right.

[Erich]

No comments on my post? Can't really comment on much as far as CS goes as the tow plate is the first CS product I have purchased, but typically if engineers for a company can't get the simple stuff correct I have a hard time trusting the more complex stuff. Which is too bad, because the coil overs sound promising.

[06Speed6]

Yeah I have been pushing the skid plate, I hope it happens.

The VVT really needs to happen, our choices are DCR which takes forever has has almost no support or communication and PTP who is banned here for vendor issues.

In for a oil cooler adapter, there could be a massve market for it because the ford focus uses the same block adapter and no one makes one.


The tb bypass hose would be nice because you eouldnt be rigging your car, it would really be paired with some plugs for the tb.

I am doing a cam gb and honestly there is no reason that there shouldnt be cams available.

The front engine mount goes from the radiator support to the block behind the a/c compressor.

Ive nearly machined a dual cdfp bracket, if the pumps were phased such that one pump would be at a lobe peak while the other pump would be on the base circle so that the pressure spike frequency would be doubled instead of the amplitude.

An exhaust that doesnt rattle at the metal decorative ring things at the rear bumper

[maddocx240]

yeah a few people have been having issues with the welding on your fmic..i only only know of the ms6 guys, dont know about the ms3.. one guy even said the ones you sent him as a replacement leaked as well.. i have the ram air fmic on my ms6 and have no issues but others arent so lucky.. and another complaint was the silicone coupler for the hotpipe on the fmic being too small (which it is btw) where you have to use the stock turbo tube which has the better bend, that needs to be corrected as well..