Alloy Wheel Welding &
Crack Repairs
in Exeter

Cracked alloy wheels are dangerous — but replacement is not always necessary. Our TIG welding repairs restore structural integrity, saving you hundreds compared to new wheels.

Specialist alloy welding with full structural assessment. If it is not safe to repair, we tell you straight.

What Is Alloy Wheel Welding?

Alloy wheel welding is a specialist repair process used to fix cracks in aluminium alloy wheels. Using TIG (Tungsten Inert Gas) welding, we fuse the cracked sections back together with matching aluminium filler rod, restoring the structural integrity of the wheel.

Cracks in alloy wheels are caused by severe impacts — potholes, speed bumps taken too fast, or hitting debris. They can also develop from metal fatigue on older wheels that have been subjected to years of stress. A crack allows air to escape from the tyre and, if left unrepaired, can propagate across the wheel and lead to catastrophic failure.

Not every crack is repairable. The location, length, and direction of the crack all determine whether welding is a safe and viable option. Cracks on the rim lip and barrel are generally repairable. Cracks through the spoke face or hub area are higher risk and may not be suitable for welding. We assess every crack individually before recommending a course of action.

At South West Alloys, we combine welding with cosmetic finishing so the repair is invisible. After welding, the affected area is ground smooth, filled if necessary, and refinished to match the rest of the wheel. The result is a structurally sound wheel that looks as good as new.

Why Ignoring a Cracked Wheel Is Dangerous

A cracked alloy wheel is a structural failure — not a cosmetic issue. The crack allows air to escape from the tyre, often presenting as a slow puncture that keeps returning despite repeated tyre replacements or re-seating attempts. This alone makes the vehicle unsafe.

More critically, cracks propagate under load. Every pothole, bump, and braking event applies stress to the wheel. A small crack grows larger with each cycle of use. What starts as a hairline fracture on the inner rim can spread across the barrel and eventually cause the wheel to split apart — potentially at speed.

Many drivers do not realise their wheel is cracked. Cracks on the inner barrel or behind spokes are invisible without removing the tyre. If you are experiencing persistent slow punctures or unusual vibrations that tyre balancing cannot fix, a crack may be the underlying cause.

The cost of ignoring a crack extends beyond the wheel itself. A sudden blowout caused by wheel failure can damage the wheel arch, bodywork, suspension, and brake components — turning a £100 weld into a £3,000+ repair bill. Early assessment and repair eliminates this risk entirely.

Welding Methods, Materials & Limitations

We use AC TIG (Alternating Current Tungsten Inert Gas) welding for all alloy wheel crack repairs. AC TIG is the industry-standard method for welding aluminium alloys because it provides excellent heat control, clean welds, and full penetration through the crack.

The filler rod used matches the aluminium alloy composition of the wheel — typically 4043 or 5356 grade aluminium filler. This ensures the weld has similar strength, ductility, and corrosion resistance to the parent metal. Using incorrect filler material is one of the most common mistakes made by inexperienced repairers.

Pre-weld preparation is critical. The crack area must be cleaned of all paint, lacquer, and oxidation. The crack is ground out to a V-profile to allow full weld penetration. Any contamination in the weld zone will cause porosity — air pockets that weaken the repair. Our preparation process eliminates this risk.

Location determines repairability. Rim lip cracks — caused by kerb impacts — are the most straightforward to weld and have the highest success rate. Barrel cracks from pothole damage are also generally repairable. Spoke cracks carry higher structural risk because spokes bear the vehicle's weight and braking forces. Hub cracks — near the bolt holes — are rarely recommended for welding due to the extreme stress concentrations in this area.

After welding, we recommend full cosmetic refurbishment of the affected wheel. This is not just for appearance — the new lacquer layer provides corrosion protection over the weld area, which would otherwise be exposed bare metal. We offer combined weld-and-refurbish pricing that saves money compared to separate bookings.

For wheels where welding is not safe, we will advise on replacement options. We can source matching OEM or aftermarket replacement wheels for most vehicles and refurbish them to match your remaining set.

Frequently Asked Questions