CorkSport Max Flow High Pressure Fuel Pump Upgrade Pre-Order

[SpencerC]

Originally Posted by ihasmazda I just got this installed this weekend. Am I the only one who didn't need the tools whatsoever? After tapping it in via screwdriver handle as instructed, the tappet didn't stay inside of the spring retainer and would keep falling out, and it would just press right back in by hand... It made me a little nervous but it seems to be running OK and i saw a brief pressure reading of 1850 so far, so I'm assuming that it's working fine... it seems to be a lot quieter than the stocker which is nice.

Interesting. You will be fine as long as it got installed. Once the whole thing is installed there is enough pressure/tension etc. from the sleeve on the tappit that it won't come out. Give me a call if you have any questions 360-260-2675 ext 105.

[gmoney542]

I installed mine last weekend. I didn't have any issues getting the tappet into the spring retainer. I just used the tools and tapped it in with a screwdriver handle.

I did however have a couple issues, none related to the new internals but rather removing the stock internals. I think the instructions could be a little better in describing how to remove them. I also blame myself for being a noob, I'm glad I had my brother there to help out, DON'T DO YOUR FP INTERNALS ALONE NOOB!

Following Corksports intructions, the high pressure fuel line is a real pain in the ass. I think it would probably be quicker and easier to just remove the battery and intake/turbo inlet to actually have good access the the nut. Without doing that it's a world of quarter turns, smashed fingers, and doing some gymnastics and shit with your wrenches to find an angle that they'll actually go onto the nut. MAKE THINGS EASIER FOR YOURSELF. JUST TAKE OUT THE BATTERY AND TIP. SERIOUSLY. THIS DOESN'T HAVE TO BE HARD.

The first issue I had was removing the seal screw from the pump. I didn't realize at first that you have to push down on your socket and compress the spring a little to get the socket to fully sit on the nut. Or maybe my deep wall wasn't deep enough? I nearly shit myself during this bit because I didn't realize that at first, and thought I rounded the nut like a dumb ass. I did actually round the top .5-1mm of the nut because that's how much of the socket would sit on it without compressing the spring, luckily the nut is a lot taller than that, otherwise I would have royally fucked myself and be needing a pricey new pump. You should also use an impact wrench for this part. If you don't have one you should immediately cancel any plans you had in life and go get one. Don't you dare try and use an impact to put that shit back in though, I will find you and smack the shit out of you with a bag of dicks if you try that. DON'T MAKE MY MISTAKE. PUSH THAT SHIT DOWN WHEN REMOVING AND INSTALLING THE SEAL SCREW!

The second issue I ran into was actually getting the stock internals out of the seal screw. All installation instructions and videos I've watched say this is easy as pie and just use your fingernail and lift them out, I'm convinced that this is the way it should be and that mine just hate me. Well I don't know what kind of fingernails you people have but I don't think I would have been able to do it that way even if they were stainless steel. I tried to pry them out with my fingers and a screwdriver for like 30 minutes. No matter what I did those OEM bitches would not come out of there. I ended up using the 12 ton shop press and just pushed them out. MY STOCK INTERNALS WERE ANNOYING CUNTS. I HOPE YOURS DON'T HATE YOU LIKE MINE HATE ME.

My third issue, which was really just a complete failure on my end, was the gas safe container. Gas safe container means get a gas safe container. A red solo cup is not a gas safe container. If you use a red solo cup as your gas safe container you will try to pick it up at some point to move it on your work bench. When you try to pick it up the whole top half down to wherever your gas is will magically detach itself from the rest of the cup. You'll think WTF? The fuck just happened? Is this real life? Then when you realize that your gas safe container is melting onto your work bench, because of all available choices your dumb ass picked a red fucking solo cup to put gas in. Then it's all Oh shit! Oh shit! Shittttt! Fuck! Fuck! OH SHIT! FUCK! as you freak out and quickly remove your nice new internals from your cup and try to pick that melting shit up and get it outside your garage. While doing this the cup will fall apart in your hands and you will spill gas all over the fucking place and hopefully there is nothing around to catch your house on fire. A side effect of this will be you looking like a complete retard juggling a melting cup full of gas and screaming profane language. Many lulz are to be had by anyone around to watch you during this process, you will then join in the lulz because you're a dumb ass and just went full retard. DON'T GO FULL RETARD. A RED SOLO CUP IS NOT A GAS SAFE CONTAINER. CORKSPORT CANNOT BE HELD LIABLE IN ANY WAY IF YOU USE YOUR INTERNALS INSTALL AS A WAY TO BURN YOUR HOUSE DOWN TO COLLECT INSURANCE MONEY.

Holy shit that is a lot of text. Anyways, that's about how my internals install went. Not really that bad of an install, it's pretty easy. It's not enjoyable at all though and for me it was a PITA. Just make sure you pay attention and keep everything clean. This is not the install you want to fuck up!

I've got about 150 mile on these internals now and everything is going good. I went WOT for the first time today. Here are two WOT logs comparing OEM vs. Corksport.

[SpencerC]

Originally Posted by DoMiNic My only thought is that it will be "All Good" until your spill valve malfuctions from 2000+ fp pressure over working it. @Spencer@CorkSport; Have you logged pressures over 1800+ during your time with this?

Sorry about the late response, didn't realize you were asking me directly the questions. Major read fail on my part.

In answer though, yes I saw it maybe once or twice right after letting off of WOT for just a short second. Now that I am running Stage II CS specific maps I haven't seen it at all. If I remember right I only saw the 2000+ pressure on the Cobb OTS, it didn't show up on the stock map, or Stratified.

[2.0t03speed]

Originally Posted by gmoney542 A red solo cup is not a gas safe container. If you use a red solo cup as your gas safe container you will try to pick it up at some point to move it on your work bench. When you try to pick it up the whole top half down to wherever your gas is will magically detach itself from the rest of the cup.

you mean like this? we used one to hold @Rokusek; catch can contents along time ago and had it happen to us lol

[silvapain]

Originally Posted by Spencer@CorkSport Sorry about the late response, didn't realize you were asking me directly the questions. Major read fail on my part. In answer though, yes I saw it maybe once or twice right after letting off of WOT for just a short second. Now that I am running Stage II CS specific maps I haven't seen it at all. If I remember right I only saw the 2000+ pressure on the Cobb OTS, it didn't show up on the stock map, or Stratified.

The fuel pressure tables can be easily adjusted to prevent over pressurizing the system and causing the relief valve to fail. There are threads about it on MSF, showing suggested tables.

[cnote308]

Originally Posted by Spencer@CorkSport Sorry about the late response, didn't realize you were asking me directly the questions. Major read fail on my part. In answer though, yes I saw it maybe once or twice right after letting off of WOT for just a short second. Now that I am running Stage II CS specific maps I haven't seen it at all. If I remember right I only saw the 2000+ pressure on the Cobb OTS, it didn't show up on the stock map, or Stratified.

Looks like the same thing is happening to gmoney542; right after letting off WOT fuel pressure goes to 1997psi. Is this considered safe since it's only for a split second?

[Rokusek]

Originally Posted by 2.0t03speed you mean like this? we used one to hold Rokusek; catch can contents along time ago and had it happen to us lol

HAHAHA!!!! The good ole trouble shooting days after the motor build!

[gmoney542]

Originally Posted by 2.0t03speed you mean like this? we used one to hold @Rokusek; catch can contents along time ago and had it happen to us lol

Hahahaha! Yeah pretty much exactly like that. Glad I'm not the only one trying to use solo cups. It definitely wasn't something I was expecting to happen. I sorta just stared at it for a few seconds when the whole top of the cup came off lol

[[R]usty]

Toby Keith - Red Solo Cup (Unedited Version) - YouTube

Toby Keith - Red Solo Cup (Unedited Version) - YouTube

[boatis]

installed my internals yesterday in under 2 hours

[Gr33ntumb]

Good for you.

Anything useful to post? Log or something?



Sent from my SGH-I317M using Tapatalk 2

[boatis]

Originally Posted by Gr33ntumb Good for you. Anything useful to post? Log or something? Sent from my SGH-I317M using Tapatalk 2

I'll post some logs later tonight.

[Tokay444]

is there something useful in the works to harness the "extra flow" and higher pressures for benefit? or is the major selling feature of the internals, which for now has to be tuned out, redundant?

[gmoney542]

Corksport says they're developing new injectors. Hopefully they actually go through with it and will bring them to market. I suspect they would be able to utilize the extra flow offered by their internals. Though I'd bet it'll be a year or two until injectors are completed and available.

[Tokay444]

no. injectors won't help with over pressurizing the relief valve, or the scalars in the ecu for the relief valve.

[Tokay444]

let correct myself slightly uncorking some of the restriction from the injectors MAY keep from over pressurizing the rv.

[mrmonk7663]

My rail valve maxes out at 2073 evertime I let off the gas from boost. No tweaking of my fuel tables will correct it. I am running a 1975psi crack pressure valve though. I see fuel pressures as high as 2000psi at points during a run, which is great...just wish it didn't max the valve when letting off the throttle.

[DoMiNic]

Originally Posted by mrmonk7663 My rail valve maxes out at 2073 evertime I let off the gas from boost. No tweaking of my fuel tables will correct it. I am running a 1975psi crack pressure valve though. I see fuel pressures as high as 2000psi at points during a run, which is great...just wish it didn't max the valve when letting off the throttle.

I don't understand what is great about 2000psi? It would be great if it stayed between 1700 and 1800. Maxing the valve will cause failure in time. This is the problem that many tuners and seasoned MSFers are warning about. Wonder why you can change the fuel tables to correct it?

[mrmonk7663]

I do not have a stock valve...normally the valve runs under the crack pressure...it spikes just like the oem valve spikes with autotechs. No issue there. The issue is when letting off the throttle.

[bstover17]

Any truth to the rumors that these have been silently recalled? I have a friend that wanted to order a set and was just wondering.

[Bluedvl]

Originally Posted by bstover17 Any truth to the rumors that these have been silently recalled? I have a friend that wanted to order a set and was just wondering.

Was about to ask the same question. Heard a few people say they have received calls.

[mionky]

Got a call about 15 minutes ago. Definitely recalled. They said they would give me a refund or replacement. Will be a month or so for the replacement.

[Deldran]

Originally Posted by mionky Got a call about 15 minutes ago. Definitely recalled. They said they would give me a refund or replacement. Will be a month or so for the replacement.

Did they state any reasoning for the recall

Sent from my XT1080 using Tapatalk

[Tokay444]

not silently.
Fuel Pump Woes

[CorkSport]

Today, we learned that our recently released fuel pump internals were not manufactured to specification. As a result, we are recalling all pump internals kits sold to date.

Our original designed and validated internals functions as intended. We did our due diligence on the design. However, they were not manufactured in volume correctly and we failed to catch the error internally.

All customers are being offered a 100% refund, including shipping cost or a $200 store credit if they choose to wait for replacements, which are 4-6 weeks out the best we can estimate.



Unfortunately, we did not do our due diligence on quality control of the first batch. The “Sleeve” was manufactured about 0.2mm larger than we designed and tested. This results in the sleeve not fully seating inside the pump housing. This can cause the spring to bind and eventually the pump to fail.

We have had one customer break a pump and we have replaced it. We will do the same for any other customer affected.

We have already reached as many customers as we could by phone and sent an email out to all the others with a 24/7 cell phone number to answer questions.

We take this matter very seriously. We have erred in quality control. We appreciate the trust you place in the CorkSport brand and we will do everything in our power to rebuild that trust.

Sincerely,
Richard Harris
President

[shaneski]

Was there a beta test program done with these like the BPV (the beta testers did get to share experiences on here with the bpv..if the pistons in these stick like some of the beta BPVs it wil be a bit more severe than a bit of flutter.
All the parts i have on my car from you guys are fantastic so far but with fuel delivery it can be very expensive if something fucks up after the initial grin.

Originally Posted by CorkSport These have been in physical testing for well over a year. This is a very important part to us and we wanted to be more than just confident in its ability. Cheers, Joel

I'm sure it will end up resolved but not doing extensive quality control on a part like this of the first production batch after piston issues with the Beta BPV is a massive worry for future engine parts you guys want to market that can result in ZZB.
.

[hnda etr]

Originally Posted by shaneski Was there a beta test program done with these like the BPV (the beta testers did get to share experiences on here with the bpv..if the pistons in these stick like some of the beta BPVs it wil be a bit more severe than a bit of flutter. All the parts i have on my car from you guys are fantastic so far but with fuel delivery it can be very expensive if something fucks up after the initial grin. I'm sure it will end up resolved but not doing extensive quality control on a part like this of the first production batch after piston issues with the Beta BPV is a massive worry for future engine parts you guys want to market that can result in ZZB. .

Beta test parts are normally produced in small batches and highly qa'd. Small batches so that a lot of parts and money isn't lost in case a revision is needed and highly qa'd to make sure the parts meet specs.

So beta testing would probably have resulted in nothing reported.

[shaneski]

Originally Posted by hnda etr Beta test parts are normally produced in small batches and highly qa'd. Small batches so that a lot of parts and money isn't lost in case a revision is needed and highly qa'd to make sure the parts meet specs. So beta testing would probably have resulted in nothing reported.

I get what you are saying but my point was more the quality control on the piston part on such a vital engine part after the piston design itself on the beta BPV was off..PT John had his fail on the first revision and i think KMD had some batches fail cause of Manufacture fuck ups.

First production batch to gain a market share you would want to check them yourself for defects before even think of shipping since people are so fussy with these (and for good reason)

[hnda etr]

Originally Posted by shaneski I get what you are saying but my point was more the quality control on the piston part on such a vital engine part after the piston design itself on the beta BPV was off..PT John had his fail on the first revision and i think KMD had some batches fail cause of Manufacture fuck ups. First production batch to gain a market share you would want to check them yourself for defects before even think of shipping since people are so fussy with these (and for good reason)

John's 2nd batch was the one with the problem, iirc, his first batch was in a small quantity that only a few people got... His problem was the same as CS lol - when the manufacturer ran the large production batch, tolerances were off.

You are totally correct that QA on the production pieces should have been done better though...

[dale_gribble]

Designing a tolerance and manufacturing to that tolerance are two different things.

Glad that CS is doing the right thing, sucks that they got in this situation. I'm rooting for them, but it's a different game building these kind of parts vs. the standard bolt ons. There's a reason there are only like 2 manufacturers of these parts and there is a reason two little pieces of machined metal cost so much. Probably 75% of the cost is machining and qc. The cost of the metal itself is relatively cheap.

My day job lives or dies being able to hit critical to function parameters so I understand cs' s plight. It ain't easy or else everyone would do it.

[hnda etr]

Originally Posted by dale_gribble Designing a tolerance and manufacturing to that tolerance are two different things. Glad that CS is doing the right thing, sucks that they got in this situation. I'm rooting for them, but it's a different game building these kind of parts vs. the standard bolt ons. There's a reason there are only like 2 manufacturers of these parts and there is a reason two little pieces of machined metal cost so much. Probably 75% of the cost is machining and qc. The cost of the metal itself is relatively cheap. My day job lives or dies being able to hit critical to function parameters so I understand cs' s plight. It ain't easy or else everyone would do it.

KMD
Autotech
CPe (rebranded)
DFDD (PTP)
Now CS
-----------
5 manufacturers lol

That's also the problem with not building in-house and having to outsource manufacturing - have to rely on manufacturer's QA and tolerances...

[silvapain]

The BPV was a beta test; issues are not uncommon and the testers should have known what they were getting into.

This is a totally different issue. I don't know the details of CorkSport's particular situation, but this is usually how it goes:

The company that designs the part also determines go/no go quality metrics for the part. These are given to the manufacturer of the part along with the design. It is then up to the manufacturer to build the part and internally QC the part per the design specs.

There are many reasons a bad part can slip through the cracks.

1. The throughput of parts (rate they're made) is so high that it's not feasible or maybe even possible to check every one. So what they'll do is randomly spot check a part from a batch or lot. If that part passes, ALL parts in that batch or lot pass. If that part fails, ALL parts fail.

2. Operator error. This is the #1 cause of preventable quality issues in almost any manufacturing field. The operator improperly checks the part, or improperly documents the result of the check.

3. The manufacturer knowingly let's bad parts pass. Sad, but true. Manufacturers typically aren't paid for parts that don't pass QC, and they eat the cost of materials and labor for that failed part. So some less scrupulous manufacturers will "fudge" the numbers to minimize losses.


Tappin it

[Tokay444]

My old boss used to fudge number all the time. Always on jobs he had setup himself. And these were aircraft parts. I don't fly.
Glad I'm no longer on that sinking ship.
I know, when I had guys workin under me, we checked parts statistically, but if we found one part in a batch that was bad, we went through and checked them all, rather than just scrapping the whole batch. It was still more cost effective to lose some labour checking than potentially throw out good parts or parts which could be reworked.

[volcomcinematic]

Corksport SURE isn't looking to good...

[Deldran]

Originally Posted by Tokay444 My old boss used to fudge number all the time. Always on jobs he had setup himself. And these were aircraft parts. I don't fly. Glad I'm no longer on that sinking ship. I know, when I had guys workin under me, we checked parts statistically, but if we found one part in a batch that was bad, we went through and checked them all, rather than just scrapping the whole batch. It was still more cost effective to lose some labour checking than potentially throw out good parts or parts which could be reworked.

That's the way we do it at bower. Operators are to check a certain number of parts. Some parts have a long enough cycle time the could be checking every part but they don't make them do that. If one part is bad they check the whole lot. If its in heat treat sometimes they can be saved by fixing the setup on the machine. Some bad parts do get out though

Sent from my XT1080 using Tapatalk

[Dmurray06]

Originally Posted by volcomcinematic Corksport SURE isn't looking to good...

Apples to oranges.

[Tommy]

Originally Posted by volcomcinematic Corksport SURE isn't looking to good...

They might have royally fucked this up but they are owning it. SURE still claims their parts are perfect.

[Tokay444]

Fuck SURE.

[volcomcinematic]

I was being a dick by making that statement. I said it omce before..so I was waiting for someone to call me out on it. Hope everything works out in a serious note.

[econman]

Any update on the delivery date of the new internals? I know the original estimate was 4-6 weeks.