Can cracked alloy wheels be repaired? What's safe and what isn't
Where cracks can be welded safely, where they can't, how the repair is tested, and what it costs against a new wheel.
By the Infinity Wheelz team · Updated 18 October 2026 · 4 min read
Yes — in most cases a cracked alloy wheel can be repaired by TIG welding, and a good repair is safe, permanent and far cheaper than a new wheel. The exceptions are cracks in the spokes or hub area, and wheels that have been welded in the same place before.
How alloy wheels crack
Alloy wheels are cast aluminium. They are strong, but unlike steel they do not bend much before they crack. A sharp pothole edge, a kerb strike at speed or a low-profile tyre with little sidewall to absorb the hit can all put a hairline crack in the rim. It is usually on the inner rim where it is hard to see, and the first you know is a slow puncture.
Cracks that can be repaired
- Cracks in the inner rim barrel — the most common and the most straightforward to weld.
- Cracks on the outer rim lip from kerb strikes.
- Short cracks (under roughly 50mm) that run across rather than around the rim.
Cracks that should not be repaired
- Cracks through a spoke or where a spoke meets the rim — these carry the load and a weld cannot be trusted.
- Cracks at the hub face or around the bolt holes.
- Multiple cracks, or a crack in a wheel that has already been welded in the same spot.
- Forged wheels — some can be repaired but they need specialist assessment.
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How the repair is done
The tyre comes off and the wheel is pressure tested or dye-checked to find the full length of the crack. The crack is ground out to a V so the weld penetrates the full depth, the wheel is pre-heated, and the crack is TIG welded with a matching aluminium filler. The weld is then ground flush inside and out, and the wheel is pressure tested again before the tyre is refitted and balanced. If the impact also buckled the rim, it is straightened first.
What it costs
Crack welding at our Ipswich workshop starts at [£70] per wheel, or [£110] with straightening. An OEM replacement wheel for a modern premium car is typically £300–£600, so the repair pays for itself immediately — and it is usually back on the car within a day or two.
FAQ
Related questions
How do I know if my alloy wheel is cracked?
The usual sign is a tyre that slowly loses pressure with no nail or puncture found. Spraying soapy water around the rim will bubble at the crack.
Will a welded wheel pass an MOT?
A properly welded and dressed repair on the rim is not an MOT failure. A visible, unrepaired crack is.
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Service
Crack welding
from [£70] per wheel
Service
Wheel straightening
from [£60] per wheel
Service
Alloy wheel repair
from [£45] per wheel
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