The Waiting Game: Complications with the 4-Piston Brake Kit

[Hal]

Emerald Tuning: The waiting game...

Picture at link....


The above picture is that of my new Corksport 4-piston calipers, a washer, and the bracket upon which the caliper was supposed to mouth cleanly. The key phrase? "Supposed to." As the spacer would indicate, the install was not seamless, as 3 of the 4 mounting points were found to be either incorrectly bored, or the bolts too long. For now, I'm running spacers, and the brakes seems to be functioning properly.

Unfortunately for me, it's now Tuesday night, and I am still without word that a new set of hardware is on its way to my door. Mind you, I called Corksport on Saturday and left a voice mail about the issue, spoke to them again on Monday, and have now exchange multiple emails. Still though, no new hardware appears to be on the way. I've been told that the "engineering team" is trying to replicate the problem, which logically is actually illogical. If this was a one time quality control issue or packing problem (MS6 hardware in lieu of MS3), then there is nothing to replicate. Simply send the new hardware and we should be golden.

I've also been told to remove the Allen bolt which connects the caliper to the bracket and measure it. Again, this won't solve my problem and as a father of a two year old, married, and in a graduate studies program, making time to get the car up and work on it is a luxury (why I installed them in the first place during a NATOR install meet). A new set would need to be sent either way. Do you see why I'm frustrated? The first thing Corksport should have been done is to try to solve the customer issue immediately, which in this situation would be to send new hardware. They can always investigate on the back end, after the customer's issue is addressed. If the new hardware doesn't solve it, then it would then likely be a caliper issue, but I'm not worried that it is.

The real test of a company is not how they behave when things are going well, but how they behave when things don't. If this is any indication of how Corksport will behave in the future, count me worried. Up until now the service has been top notch, which makes this situation that much more concerning to me.

Again, the wait is on.

[SaveMelMac]

I ran into this same issue when I was using my own supplied pads which has the a extra square nub on the pads. The nub would hit the caliper bracket and cause the same issue. The nub has to be ground off.
Curious are you using the supplied CS pads?

[Hal]

Yes. Pads as they were already installed in the caliper.

The issue seems to be pretty straight forward. With the spacer they do work, and look great, but as you can imagine I'm a bit frustrated after spending $800.

I would like to have the hardware by the weekend so I can find some time to quickly swap out the bolts and bracket and see if I'm good to go.

Again, I haven't received a call, but a few emails about the engineering team looking in to it, and the request for me to measure my Allen bolts.

[SaveMelMac]

I feel your frustration. If your using their pads the issue seems pretty straight forward, with there being a hardware issue or holes not being drilled deep enough.
Hope everything gets resolved quickly

[Hal]

Thanks. We will see. I'll be sure to keep everyone informed.

[Enki]

Confirmed, took us (I was on-site for install) a couple minutes to figure out a game plan, but decided that modifying supplied hardware by burning it down with a grinder probably wasn't a good idea at the very least for warranty issues.

[Hal]

Originally Posted by Enki Confirmed, took us (I was on-site for install) a couple minutes to figure out a game plan, but decided that modifying supplied hardware by burning it down with a grinder probably wasn't a good idea at the very least for warranty issues.

Bingo.

I already saw that earlier brownie get denied warranty by modifying, hence the choice for spacers. Once the new hardware comes, I could swap it out within 15 minutes without needing to bleed again.

[SpencerC]

@Hal;

I believe our issue is that we are unsure which part is the problem. Since this is the first time running into this issue (it is different than the brake pad nub issue that some aftermarket pads have) and we have no measurements of the bolts etc. we are unsure whether it is the bracket, the caliper or bolts.

If we assume it is the bolts, we could be wrong and have also sent you the Mazdaspeed 6 bracket, in which case sending the right bolts for an MS3 would simply end up giving you what you already have, a bracket and bolt combo that requires spacers. On the flip side, if it is just the bolts that are incorrect, then yes, it is a simple fix and we just need to get the new ones out the door. At the same time if it is simply the bracket, then it also is a simple fix, and we just send you a new bracket. Regardless, we aren't sure which it is and would need a measurement to know.

Either way, I do apologize for the delay. I know that our engineers, our warehouse, our sales team and Kelly who is handling your warranty have all been communicating about this problem.

Perhaps our caution is that we are trying to find you the right solution, the first time. This is taking a little time, in comparison to sending you a solution ASAP that might not work.

I have this note from one of them to the warranty department: "we have checked 1 of the kits in stock to confirm measurements and they work on our end (we have 3mm of extra space in the threads). I can not see a way in which the same parts would do that. The bolts are 30mm long, can he verify that his are the same length? If they are I can send out brackets to him."

That was sent to Kelly yesterday less than 30 minutes before she emailed you asking you to measure the bolts.

Unfortunately since it is an inconvenience to check the bolts on your car (which I do understand since it is a daily driver) we are now trying to replicate the problem so we know if we need to send you new bolts, or a new bracket.

If there is a third solution you can think of where we can get you what you need, and you don't have to verify the length of the bolts, let us know, because we are trying 3 different brackets, and 3 different sets of bolts in multiple combinations over here in order to try and replicate your issue.

Regardless, Derrick and I will make sure that by the end of today we will be shipping you some solution, even if it is an entirely new kit.

[Hal]

How about you simply mail me the Mazdaspeed3 specific bracket and bolts. I then try just the bolts and if I have the same problem, I then try the bracket. If I still have a problem then we know it's a caliper issue, which would be strange since its 3 of the 4 mounting points, thus both calipers.

Replicating the issue would be impossible if it's a one time quality control issue. Are the MS6 bolts longer than the MS3 bolts? Are the holes bored differently? Who bores them? In house our contracted out? Same with the bolts.

Either way, my problem remains while your team continues to troubleshoot. For the sake of customer satisfaction, it would seem reasonable to overnight me new MS3 hardware, so I can report back if its resolved.

[SpencerC]

That's actually what we are planning I think. If the engineers don't have a known solution by shipping time we will just send you the hardware and probably the bracket so you can just try both and have all you need there, and whatever you don't need, send back.

[Hal]

More than happy to video tape the issue as well, take photos, etc.

I certainly think it's a one off thing. Shit happens. Just don't want this drug out too long. Would love to get this done on Saturday during my son's nap.

[ABolewski]

It sounds like CorkSport is taking care of you in a professional manner.
I understand the frustration though, believe me!
Spencer is correct in that they want to send you an appropriate fix the first time, not the second or third. They are a business, and you are a family man, things won't happen overnight.
Interested to see where the issue originated. Good luck.

[SpencerC]

Originally Posted by ABolewski It sounds like CorkSport is taking care of you in a professional manner. I understand the frustration though, believe me! Spencer is correct in that they want to send you an appropriate fix the first time, not the second or third. They are a business, and you are a family man, things won't happen overnight. Interested to see where the issue originated. Good luck.

True, but it's been 2.5 days since we knew about it, and 4.5 days for him, which feels like eternity! We have all been there!

[Hal]

Originally Posted by Spencer@CorkSport True, but it's been 2.5 days since we knew about it, and 4.5 days for him, which feels like eternity! We have all been there!

Spencer gets it.

At least I have my laser pointer to keep me busy... :-)

Oh, and the brakes feel great....

[SpencerC]

Good news! We figured it out on our end and have the necessary components being overnight shipped to you!

Sorry about the delay.

[Enki]

Shipping mishap? Bolts too long, I'm guessing.

[SpencerC]

I wasn't told what it was exactly, just that we got it solved and are sending them. I assume it was just a bolt issue too.

[Tokay444]

A washer IN the counter bore of the caliper would have been a better solution than underneath it.

[Hal]

Originally Posted by Tokay444 A washer IN the counter bore of the caliper would have been a better solution than underneath it.

Wasnt available at the time.

Received a nice call from Derek at CS today about the new hardware.

Being shipped overnight which is brilliant. Will see about getting the new hardware on the car Saturday during my son's nap.

Will post results. I don't expect any trouble.

[KCi]

Great after-sales service from Corksport!

[Hal]

YouTube Short

YouTube Short

[Code Monkey]

"Haven't driven them yet but I assume they will perform." --> GTFO

[Hal]

On the mountain....

[Tokay444]

I would have pointed the bleeders downward, personally, but I see the logic in pointing them up. Bubbles float.
I have power bleeder so nce. They're going down.

[SaveMelMac]

Glad to see it all worked out. No complaints with my kit here