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post #1 of 12 (permalink) Old 06-28-2013, 12:36 AM Thread Starter
Frnchplayr15
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Product Warning for CS new BBK

Well just want to give you all a heads up!!! Already been tested and not good news. Hope you guys fix this.
I'll keep an eye on what gets done.
** PRODUCT WARNING ** - Corksport 4 Piston BBK - Mazdaspeed Forums


Phil



Quote:
Originally Posted by Haltech View Post
@CorkSport ;
@Joel@CorkSport ;
@Austin@Corksport ;

Today i met up Nator Socal @UnknownSuperhero ; and @bryces_speed3 ; to knock out a quick install for the 4 Piston Brake Kit. Everything went as planned... everything bolted up, no snags.. great quality hardware including grade 8 allens for the caliper to bracket mounting.

The snag? Brake lines... I don't know if someone ordered the wrong brake lines and didn't bother to double check the part#'s on the lines or they never used these on the test vehicle., but the banjo bolt itself, is to long to go into the caliper. How do we know this? The crush washers which are coated silver wont crush.

They won't crush because the washers are to big in diameter for the banjo bolt itself, yet they are to THIN to be crushed; they need to big THICKER. What happens is, CS states the brake line to calp is to be torqued to 15-19 ft lbs. If you try that, then pressurize the system to bleed (powerbleeder) you get this awesome blue flow of fluid pissing out onto the ground from the back of the caliper.

When i say pissing, i mean pissing. So, that tells me the washer didn't crush... lets give it some torque... (directions said 15-19 and it didn't work, so lets see if it works at all) nope, still nothing... still pissing... more torque? ... sure.. lets take it to the point of no return... Its still pissing Greg... a little more... Nope, still pissing... What could be wrong? Bryce, break the line loose and lets see what's up... Now.. I knew, there was a great chance of this banjo bolt snapping, but it didn't snap until Bryce cracked it loose... It gave us an opportunity to see what happened...

The bolt bottomed out because its too long.. the washers, not being thick enough nor "crushable", are not helping this bolt. Greg and Bryce are very familiar with banjo bolts as they have dealt with some of their snags on BT installs out here. Greg spotted it immediately that the bolt was spewing fluid because it bottomed out and the washers did nothing. It would of taken some serious 15mm washers to stop the leak., but that i still a bandaid fix. Greg suggested that the banjo fitting setup was to small and should be enlarged. Greg pointed to his Bryce's Suzuki and said those banjos are no larger than on the front brake on that bike.

What's important here is, i do not want to see anyone installing this kit, then realizing it must be their brake line not installed correctly, doing a hack patch only to end up dead. Hey, we're all pretty smart here, but sometimes people don't want to wait or try to muster a temp solution... i never put it past a human being doing something stupid.

At any rate, it was a real shitty evening and having to put the car back to stock brakes again royally sucked. But not as much as the 2 cans of brake fluid wasted.. Don't ask....


Corksport needs to address these lines. I then want them sent to me for testing. If they are deemed acceptable and safe, ill let them know to send them out to everyone else. This detail is way to important and cannot be overlooked. I am not sure what happened, but as a paying customer on this product, i am pretty disappointed and pissed off.

This is why i ask vendors to send me their stuff for testing before retail. This would of been caught and addressed immediately. It would of saved a whole lot of headache, shipping cost and loss of confidence Corksport now has from me, the owner. I know i told Joel several times in shout, that this kit should be sent to me before retail for this very reason... catching something before are hell breaks loose.

At any rate.. i'm attaching resized images and a direct download to the high res pictures of the issue.




2013 Mazdaspeed 3 Tech pack

M2 Performance Catless Long Downpipe // UR CBE // All bulb's are V-LED's // RA Mudflaps // STI 06-07 Chargespeed Lip // Rear LED Reflectors // Autotech Internals // COBB Accessport v3 // JBR OCC Stage 2 // JBR SSP Kit // JBR SSB // JBR Stage 2 Intake // JBR TIP // CP-E RMM // SPC Camber Arms // Forge BPV v2 // Hella Supertones // BC Coilovers // CS RSB // NGK IX Iridium 1SC Plugs // RPF1's 17x9 +45 // BFG Super Sport Comp 2 255/40/17

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post #2 of 12 (permalink) Old 06-28-2013, 12:53 AM
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Thanks for the heads up! Has there been actual tests that proves it stops the car better or no?
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post #3 of 12 (permalink) Old 06-28-2013, 12:54 AM
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Quote:
Originally Posted by pdc001 View Post
Thanks for the heads up! Has there been actual tests that proves it stops the car better or no?
According to corksport no. They have no numbers to prove anything yet
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post #4 of 12 (permalink) Old 06-28-2013, 12:55 AM Thread Starter
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Quote:
Originally Posted by pdc001 View Post
Thanks for the heads up! Has there been actual tests that proves it stops the car better or no?
I don't think so but I'm still reading the thread its only been out for a week but kevin has had it for a bit longer I think

2013 Mazdaspeed 3 Tech pack

M2 Performance Catless Long Downpipe // UR CBE // All bulb's are V-LED's // RA Mudflaps // STI 06-07 Chargespeed Lip // Rear LED Reflectors // Autotech Internals // COBB Accessport v3 // JBR OCC Stage 2 // JBR SSP Kit // JBR SSB // JBR Stage 2 Intake // JBR TIP // CP-E RMM // SPC Camber Arms // Forge BPV v2 // Hella Supertones // BC Coilovers // CS RSB // NGK IX Iridium 1SC Plugs // RPF1's 17x9 +45 // BFG Super Sport Comp 2 255/40/17

Next things to buy:
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GV Grill
BNR S3
Guardian Angel from Stratisfied
FMIC

2010 Mazda 3 iSport- SOLD




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post #5 of 12 (permalink) Old 06-28-2013, 01:31 AM
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Kevin (Haltech) also said that when he installs the CS BBK he's not going to use the pads CS provides. He going to use Ferrodo 2500's so any stopping distance info he provides won't be valid because most people will use the pads CS provides.

He's doing the worst thing possible, providing a review with parts other than what's provided with the kit.

NWMotive has a kit installed on his car already, here's a pic. I actually think this BBK isn't a BBK kit at all. 4 pot calipers on a BBK are normally on the rear not the front. If CS's BBK had 6 pot with 356 mm rotors for the front and 4 pot and 330mm rotors for the rear then they would look really kool. Our cars don't really need 6 pot front calipers but for looks they can't be beat. Oh well.
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Last edited by warlord; 06-28-2013 at 02:46 AM.
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post #6 of 12 (permalink) Old 06-28-2013, 10:36 AM
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Just so everyone knows.

We are looking into this issue. We want to have a direct answer for everyone as soon as we can. We must look into all the issues before we can give a direct response though, so give us a little time. Currently we are waiting for the parts from Kevin (Haltech on MSF) to come back and then we will be inspecting those. We have also been doing some of our own testing and installs.

Also, NWMotiv does have the kit already installed and he has had no issues.

Feel free to PM me with any questions or concerns. I will try my best to help you. Of course we are always just a phone call away also. 360-260-2675 ext. 105 for me directly.
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post #7 of 12 (permalink) Old 06-28-2013, 10:37 AM
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Just waiting for another fail


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post #8 of 12 (permalink) Old 06-28-2013, 06:35 PM
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So if you haven't seen alright, we did our research, did our testing and have released our findings. Below you will find 2 videos from an install we did yesterday from start to finish, and a slideshow of unclear areas in our instructions that we have corrected.

CorkSport Mazda 3 / Mazdaspeed 3 Big Brake Caliper Kit Install Video - YouTube
How to Bleed CorkSport Big Brake Caliper Kit - YouTube

This is a direct copy from Mazdaspeed Forum

"I want to first say thanks to Kevin for working with me on this, I had many questions for him and Shawn and I never had an issue getting those answers that I needed. I would also like to let the community know that in the past 36 hours CorkSport as a company has spent almost 30 man hours investigating this issue and trying to re-create it. Below is a slide show encapsulation of my investigation and evidence. We will be incorporating some changes to the instructions and Kevin will be making another pass at this install very soon. One more thanks to the patient forum members who were kind enough to let me go about this analytically and get all the facts. I don't want to make excuses, blame people or reach at straws; I want data and answers. I wish we had a firm conclusion, but you can rest assured that this matter was/is taken VERY seriously."













Thank you all. Feel free to call us or PM us with any questions.
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post #9 of 12 (permalink) Old 06-28-2013, 07:25 PM
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Garage
Thank you for the quick update and response to the issue.


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post #10 of 12 (permalink) Old 06-28-2013, 08:45 PM Thread Starter
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Thanks Spencer! @Spencer@CorkSport

2013 Mazdaspeed 3 Tech pack

M2 Performance Catless Long Downpipe // UR CBE // All bulb's are V-LED's // RA Mudflaps // STI 06-07 Chargespeed Lip // Rear LED Reflectors // Autotech Internals // COBB Accessport v3 // JBR OCC Stage 2 // JBR SSP Kit // JBR SSB // JBR Stage 2 Intake // JBR TIP // CP-E RMM // SPC Camber Arms // Forge BPV v2 // Hella Supertones // BC Coilovers // CS RSB // NGK IX Iridium 1SC Plugs // RPF1's 17x9 +45 // BFG Super Sport Comp 2 255/40/17

Next things to buy:
PMM and TMM
GV Grill
BNR S3
Guardian Angel from Stratisfied
FMIC

2010 Mazda 3 iSport- SOLD




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