Alloy Wheel Welding: Everything You Need to Know

8 February 2025

Before and after alloy wheel welding and refinishing carried out at Mario’s Wheel Repairs workshop in London.

Alloy Wheel Welding – Safety, MOT Advice & Expert Repairs in London & Essex

At Mario’s Wheel Repairs, we’ve been welding and restoring alloy wheels for over 13 years, serving customers across London, Essex and surrounding areas. Using advanced TIG welding to industry standards (ISO 16949 / SAE J2530), we ensure every repair is structurally sound, MOT‑compliant and built to last.

13+ Years TIG / Pulsed TIG MOT‑compliant

Close-up of a multi-spoke alloy wheel with kerb and impact damage before welding. — Before: multi‑spoke wheel with kerb/impact damage

What is Alloy Wheel Welding?

Alloy wheel welding is a specialist repair process used to fix cracks and structural damage in alloy wheels. It involves fusing compatible metal to restore the wheel’s integrity and prevent further deterioration. If left untreated, even a small crack can lead to a flat tyre, MOT failure or complete wheel collapse.

Is it Safe to Weld Alloy Wheels?

Yes—when performed by a skilled, qualified technician using the right equipment. Many drivers believe welding compromises wheel strength, but a correctly executed weld restores structural performance. We follow industry standards and carry out post‑weld testing to ensure your wheel is safe for road use.

Cracked Alloy Wheel Repair

Cracks often occur from potholes, kerbs, or rough road conditions. Severe impacts can cause buckling, which further weakens the wheel’s performance and safety. Ignoring these defects risks sudden failure while driving.

How to Identify a Crack

Gradual loss of tyre pressure without visible puncture
Unusual vibrations or pulling while driving
Visible cracks or distortion on spokes or rim edges

Workshop tip: After a pothole hit, check for new vibrations between 50–70 mph and recheck tyre pressure within 24–48 hours.

MOT & Insurance

Cracked wheels can cause an MOT failure if structural integrity is compromised.

Professionally welded wheels will pass where the repair meets standard and integrity is restored. Poor or incomplete welds may fail.

Insurers vary in policy on welded wheels. We provide:

Before/after photos
Invoice noting compliance with ISO/SAE standards
Details of welding method and filler alloy used

How Long Does Alloy Wheel Welding Take?

Typical timeframes for common welding scenarios
Scenario	Typical Time
Simple rim‑edge crack	A few hours
Crack near hub + straightening	Up to a full day
Heat‑sensitive alloys (e.g., magnesium)	Extended prep/cooling

Welding Techniques for Alloy Wheels

TIG (Tungsten Inert Gas): Precise heat control; preferred for alloys.
MIG (Metal Inert Gas): Faster, less precise; generally avoided for high‑performance wheels.
Pulsed TIG: Better temperature control for heat‑sensitive materials.

Risks of Poor Welding

Heat distortion affecting balance
Incomplete crack penetration weakening the repair
Incorrect filler alloy causing galvanic corrosion

Alternatives to Welding

Wheel Replacement: Safest for severe or multiple cracks.
Professional Refurbishment: For cosmetic damage only – doesn’t fix structural cracks.

See more transformations in our gallery.

Typical Costs: Welding from £70 per wheel depending on crack size, position and material. Refinishing (e.g., powder coat) priced separately if required.

A cracked wheel won’t repair itself—and will only get worse with time. Professional welding can restore strength, extend lifespan, and keep your car MOT‑compliant.

Call 020 7859 4773 Get directions Serving London, Essex & surrounding areas