Alloy Wheel Welding: Everything You Need to Know
Alloy Wheel Welding in London: Safety Checks, Crack Repairs & MOT-Ready Results
Alloy wheel welding is a safety-critical repair — and it’s not suitable for every wheel. At Mario’s Wheel Repair, we assess each wheel individually, weld only when it’s structurally appropriate, and verify the result with practical post-repair checks (leak testing, run-out measurement, and balance checks where needed).
Can you weld a cracked alloy wheel?
Often yes — if the crack is in a repairable area and the wheel is otherwise structurally sound. Some cracks should never be welded, and replacement is the safer option.
Will it pass an MOT?
A crack that compromises the wheel can lead to an MOT fail. A professional repair may pass if the wheel is structurally sound at inspection time.
How long does it take?
Simple crack repairs can be completed in a few hours. Repairs requiring straightening and refinishing can take longer — sometimes up to a full day.
What is Alloy Wheel Welding?
Alloy wheel welding is a specialist repair process used to restore a wheel that has cracked or suffered structural damage. The damaged area is prepared, then compatible filler material is fused into place using controlled heat and technique (commonly TIG for alloys). Done correctly, welding can restore integrity and prevent a defect worsening under real road loads.
Left untreated, even a small crack can lead to a slow leak, sudden pressure loss, vibration, tyre bead sealing issues, and in severe cases, wheel failure.
Is it Safe to Weld Alloy Wheels?
It can be safe when the wheel is suitable for repair and the weld is completed by a qualified technician using the correct process. The key is not “can it be welded?” but “should it be welded?” — based on crack position, wheel condition, and whether post-repair checks confirm it’s road-worthy.
Cracked Alloy Wheel Repair: What to Look For
Cracks usually happen after pothole impacts, kerb strikes, or repeated stress. Severe impacts can also cause buckling, which changes load distribution and can make cracks more likely.
Common signs of a crack
- Tyre pressure drops without a puncture
- New vibration between 50–70 mph (especially after an impact)
- Steering feels unsettled, or the car pulls on certain roads
- Visible line/crack near the rim edge, spokes, or inner barrel
When We Will Not Weld a Wheel
Saying “no” is part of professional wheel safety. We may recommend replacement when repair would be unreliable or unsafe.
- Cracks in high-stress areas (e.g., near bolt holes, hub area, or spoke junctions)
- Multiple cracks or evidence of repeated previous repairs
- Severe structural deformation beyond safe straightening limits
- Porosity or degraded metal that cannot support a stable weld
- Damage affecting bead sealing where integrity cannot be verified after repair
Why this matters
A wheel is a load-bearing safety component. If a repair cannot be proven safe with inspection and post-repair checks, replacement is the correct outcome — even if it costs more.
Our Alloy Wheel Welding Process
Every workshop has its own workflow, but a safe wheel welding job should always include assessment, controlled repair, and verification — not just “fill the crack and paint it”.
- Inspection: visual check for cracks, deformation, corrosion, and prior repairs
- Crack confirmation: locate the full crack path (including hairline sections)
- Preparation: clean, remove contamination, and prepare the crack to accept weld properly
- Controlled TIG weld: compatible filler + controlled heat input for alloy wheels
- Finishing: dress and shape as required while protecting structural integrity
- Verification: leak check and measure run-out; balance check if required
- Refinishing options: powder coat / paint / diamond cut where appropriate (quoted separately)
MOT & Insurance
A cracked wheel can fail an MOT if the defect compromises the wheel’s structural integrity or creates a safety risk.
A professionally repaired wheel may pass if it is structurally sound at inspection time. If the repair is poor, incomplete, or the wheel remains distorted or unsafe, it may still fail.
Insurers vary. If you’re unsure, it’s sensible to ask your insurer what they require regarding repaired wheels.
- Before/after photos (where available)
- Invoice noting the repair method and wheel checks performed
- Details of any straightening and refinishing carried out
How Long Does Alloy Wheel Welding Take?
| Scenario | Typical Time |
|---|---|
| Simple rim-edge crack (repairable area) | A few hours |
| Crack repair plus straightening and checks | Up to a full day |
| Multiple defects / extended verification | Quoted after inspection |
Welding Techniques Used on Alloy Wheels
- TIG (Tungsten Inert Gas): Precise control; commonly preferred for aluminium alloy wheel repairs.
- Pulsed TIG: Helps control heat input on sensitive or thin sections.
- MIG: Can be used in some fabrication contexts, but is typically less suitable for precision crack repair on alloy wheels.
Risks of Poor Welding
- Heat distortion that affects balance and run-out
- Incomplete penetration, leaving the crack active beneath the surface
- Contamination or incorrect preparation leading to weak, porous welds
- Corrosion issues if finishing and protection steps are rushed
Alternatives to Welding
- Wheel replacement: Often the safest option for severe cracks, high-stress cracks, or multiple defects.
- Professional refurbishment: Best for cosmetic damage such as kerb rash, peeling lacquer, and corrosion — but it won’t fix structural cracks.
Want to see real results? Browse our gallery.
Typical Costs
Welding repairs typically start from £80 per wheel, depending on crack size, crack position, wheel type, preparation time, and verification checks required.
Refinishing (powder coat / paint / diamond cut) is priced separately if needed. We’ll quote clearly after inspection so you can decide whether repair or replacement makes the most sense.
A cracked wheel won’t repair itself — and defects usually worsen with time and impact. If your wheel is leaking air, vibrating, or showing damage after a pothole hit, book an inspection.
Call 020 7859 4773 Get directions Serving London, Essex & surrounding areas
