--- title: "Alloy Wheel Welding & Crack Repairs in Exeter" description: "Expert alloy wheel welding and crack repairs in Exeter. TIG welding restores structural integrity to cracked alloys. Free assessment." lang: en-GB json-ld: | [ { "@context": "https://schema.org", "@type": "Organization", "name": "South West Alloys", "url": "https://southwestalloys.com", "logo": "https://southwestalloys.com/favicon.png", "telephone": "01392 759150", "email": "contact@southwestalloys.com", "address": { "@type": "PostalAddress", "streetAddress": "Unit 3 Grace Rd W, Marsh Barton", "addressLocality": "Exeter", "postalCode": "EX2 8PU", "addressCountry": "GB" }, "areaServed": [ { "@type": "Place", "name": "Exeter" }, { "@type": "Place", "name": "Newton Abbot" }, { "@type": "Place", "name": "Torquay" }, { "@type": "Place", "name": "Paignton" }, { "@type": "Place", "name": "Exmouth" }, { "@type": "Place", "name": "Teignmouth" }, { "@type": "Place", "name": "Cullompton" }, { "@type": "Place", "name": "Crediton" } ] }, { "@context": "https://schema.org", "@type": "WebSite", "name": "South West Alloys", "url": "https://southwestalloys.com" }, { "@context": "https://schema.org", "@type": "LocalBusiness", "name": "South West Alloys", "image": "https://southwestalloys.com/favicon.png", "telephone": "01392 759150", "email": "contact@southwestalloys.com", "address": { "@type": "PostalAddress", "streetAddress": "Unit 3 Grace Rd W, Marsh Barton", "addressLocality": "Exeter", "postalCode": "EX2 8PU", "addressCountry": "GB" }, "openingHours": [ "Mo-Fr 08:30-17:00" ], "url": "https://southwestalloys.com", "priceRange": "££", "areaServed": [ "Exeter", "Newton Abbot", "Torquay", "Paignton", "Exmouth", "Teignmouth", "Cullompton", "Crediton" ] }, { "@context": "https://schema.org", "@type": "FAQPage", "mainEntity": [ { "@type": "Question", "name": "How much does alloy wheel welding cost?", "acceptedAnswer": { "@type": "Answer", "text": "Crack welding typically costs between £50–£150 depending on the crack location and length. If combined with cosmetic refurbishment, we offer package pricing. Free assessments are available." } }, { "@type": "Question", "name": "Is a welded alloy wheel safe to drive on?", "acceptedAnswer": { "@type": "Answer", "text": "Yes, when the repair is carried out correctly by a specialist using proper TIG equipment and appropriate filler material. We only complete repairs we are confident are structurally sound." } }, { "@type": "Question", "name": "How do I know if my wheel is cracked?", "acceptedAnswer": { "@type": "Answer", "text": "Persistent slow punctures that keep returning despite tyre replacement are the most common sign. Visible cracks on the rim lip are easy to spot. Inner barrel cracks require tyre removal to inspect." } }, { "@type": "Question", "name": "Can all cracked wheels be welded?", "acceptedAnswer": { "@type": "Answer", "text": "No. Cracks in the hub area or through multiple spokes may not be safe to repair. We assess every wheel individually and will not weld a wheel we consider unsafe." } }, { "@type": "Question", "name": "How long does a wheel welding repair take?", "acceptedAnswer": { "@type": "Answer", "text": "The weld itself takes 1–2 hours. Including cosmetic refinishing, most repairs are completed within 24–48 hours." } }, { "@type": "Question", "name": "Will the weld be visible?", "acceptedAnswer": { "@type": "Answer", "text": "Not once the wheel is refinished. We grind the weld flush and refinish the surface so the repair is undetectable." } }, { "@type": "Question", "name": "Can you weld and refurbish at the same time?", "acceptedAnswer": { "@type": "Answer", "text": "Yes — this is our recommended approach. Welding and refurbishing together produces the best result and costs less than two separate visits." } }, { "@type": "Question", "name": "Do you offer a guarantee on weld repairs?", "acceptedAnswer": { "@type": "Answer", "text": "Yes. All weld repairs are guaranteed against re-cracking at the weld site under normal driving conditions." } }, { "@type": "Question", "name": "What causes alloy wheels to crack?", "acceptedAnswer": { "@type": "Answer", "text": "The most common cause is impact damage — hitting potholes, speed bumps, or kerbs at speed. Older wheels can also develop fatigue cracks from years of stress cycles." } }, { "@type": "Question", "name": "Can you weld aftermarket or forged wheels?", "acceptedAnswer": { "@type": "Answer", "text": "Yes. We weld all aluminium alloy types including cast, flow-formed, and forged wheels. Forged wheels respond particularly well to welding due to their superior material properties." } } ] }, { "@context": "https://schema.org", "@type": "Service", "name": "Alloy Wheel Welding & Crack Repairs", "description": "Specialist TIG welding service for cracked alloy wheels in Exeter. Structural crack repair with cosmetic refinishing.", "provider": { "@type": "LocalBusiness", "name": "South West Alloys", "telephone": "01392 759150", "address": { "@type": "PostalAddress", "streetAddress": "Unit 3 Grace Rd W, Marsh Barton", "addressLocality": "Exeter", "postalCode": "EX2 8PU", "addressCountry": "GB" } }, "areaServed": [ "Exeter", "Newton Abbot", "Torquay", "Paignton", "Exmouth", "Teignmouth", "Cullompton", "Crediton" ] }, { "@context": "https://schema.org", "@type": "BreadcrumbList", "itemListElement": [ { "@type": "ListItem", "position": 1, "name": "Home", "item": "https://southwestalloys.com/" }, { "@type": "ListItem", "position": 2, "name": "Services", "item": "https://southwestalloys.com/services" }, { "@type": "ListItem", "position": 3, "name": "Alloy Wheel Welding & Crack Repairs", "item": "https://southwestalloys.com/services/alloy-wheel-welding" } ] } ] --- [![South West Alloys - Professional Alloy Wheel Repairs Exeter](/assets/logo-BihRv34q.png)](/) [Home](/)[About](/about) Services [Our Work](/our-work)[Reviews](/reviews)[Contact](/contact) [01392 759150](tel:01392759150)[Get a Quote](/contact) ![Damaged alloy wheel requiring professional TIG welding crack repair — South West Alloys Exeter](/assets/hero-default-CK53e2Vk.jpg) [Home](/)[Services](/services)Alloy Wheel Welding & Crack Repairs # 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. [Request a Free Estimate](/contact)[01392 759150](tel:01392759150) Specialist alloy welding with full structural assessment. If it is not safe to repair, we tell you straight. TIG Welding Specialists Structural Integrity Testing 12+ Years Experience Honest Assessments Free Crack Evaluation ## 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. ## Crack Identification & Repair This wheel had a hairline crack on the inner barrel causing a persistent slow puncture. Our dye penetrant testing identified the crack, and TIG welding restored full structural integrity. After grinding and refinishing, the repair is completely invisible. ![Close-up of alloy wheel crack damage identified during inspection at South West Alloys](/assets/wheel-damage-closeup-4Q-qMDQH.jpg) ## 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. ## Our Welding & Repair Process 1 ### Crack Identification The tyre is removed and the wheel is thoroughly inspected. We identify crack location, length, and direction. Dye penetrant testing is used for hairline cracks. 2 ### Weldability Assessment We determine whether the crack is in a safe, repairable location. Cracks in the rim, lip, or barrel are typically weldable. Hub and spoke cracks require individual assessment. 3 ### TIG Welding The crack is prepped and welded using TIG equipment with aluminium alloy filler rod. The weld penetrates fully through the crack to ensure complete structural repair. 4 ### Grinding & Finishing The weld bead is ground flush with the wheel surface. Any remaining surface irregularities are filled and shaped to match the original profile. 5 ### Cosmetic Refinish The repaired area — or the full wheel — is refinished to match the original colour and finish. The repair becomes invisible once complete. 6 ### Pressure Testing The repaired wheel is re-fitted with a tyre and pressure tested to confirm the weld holds under normal operating pressures. ## Benefits of Alloy Wheel Welding ### Restores Structural Safety A properly executed TIG weld restores the wheel to safe operating condition, eliminating the crack and preventing propagation. ### Saves Hundreds vs Replacement A weld and refinish is typically 40–60% of the cost of a replacement OEM alloy wheel. On premium wheels, the saving is even greater. ### Eliminates Persistent Slow Punctures If your slow puncture is caused by a cracked rim rather than a tyre issue, welding fixes the root cause permanently. ### Invisible Repair Combined with cosmetic refinishing, the repair is undetectable. The wheel looks factory-fresh once complete. ### Fast Turnaround Most weld repairs are completed within 24–48 hours, including cosmetic finishing. Urgent cases can be prioritised. ### Honest Assessment If a crack is not safe to weld, we tell you. We never compromise safety for revenue. Your safety is the bottom line. ## 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 ### How much does alloy wheel welding cost? ### Is a welded alloy wheel safe to drive on? ### How do I know if my wheel is cracked? ### Can all cracked wheels be welded? ### How long does a wheel welding repair take? ### Will the weld be visible? ### Can you weld and refurbish at the same time? ### Do you offer a guarantee on weld repairs? ### What causes alloy wheels to crack? ### Can you weld aftermarket or forged wheels? ### Related Services [Wheel Straightening](/services/wheel-straightening) [Alloy Wheel Refurbishment](/services/alloy-wheel-refurbishment) [Alloy Wheel Repairs](/services/alloy-wheel-repairs) [Kerb Rash Repairs](/services/kerb-rash-repairs) ### Areas We Serve [Exeter](/areas/exeter) [Newton Abbot](/areas/newton-abbot) [Torquay](/areas/torquay) [Exmouth](/areas/exmouth) ![Professional alloy wheel refurbishment results by South West Alloys Exeter](/assets/porsche-taycan-cross-turismo-night-CstBnnh1.jpg) ## Ready to Get Started? [Contact us today](/contact) for a free, no-obligation estimate. Most jobs completed within 24–48 hours. [Request a Free Estimate](/contact)[01392 759150](tel:01392759150) 12+ years experience · Trade & public welcome · German products [![South West Alloys - Alloy Wheel Repairs Exeter & Devon](/assets/logo-BihRv34q.png)](/) Professional [alloy wheel refurbishment](/services/alloy-wheel-refurbishment) serving [Exeter](/areas/exeter) and Devon for over 12 years. German products. Showroom-quality results. 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