Cracked Alloy Wheel
Repair Stockport
Cracked alloy wheel from a pothole or kerb? We perform structural TIG welding on cracked rims — safe, pressure-tested, and completed the same day. Professional workshop repair with full inspection. Get back on the road quickly without buying a new wheel.
Our Cracked Alloy Repair Service
- Structural TIG welding for cracked alloy wheels
- Inner rim barrel & lip crack repair
- Stop-drilling & deep V-groove preparation
- AC/DC TIG welding with matching filler rods
- Full dye penetrant crack inspection
- Pressure tested & balanced
- Same-day turnaround (1–2 hours)
- Full safety inspection & certification
- Honest assessment — safe repair or replace?
Cracked Alloy Wheel Repair Pricing — Stockport
Pricing depends on crack length, location, and whether the wheel has been previously repaired. We quote after inspecting a photo — no surprises.
Hairline Crack
Small inner barrel or lip crack. Quick single-pass weld, minimal preparation. Same-day.
Deep Crack
Longer crack on inner barrel requiring V-groove prep and multi-pass weld. Structural strength restored.
Complex Repair
Extensive damage, multiple cracks, or previous poor repairs. Full structural restoration required.
Send a photo on WhatsApp for an accurate quote before we book you in. Final price confirmed on inspection.
Is Your Cracked Alloy Wheel Repairable?
Not every crack can be safely repaired. Here is our definitive guide on what we can and cannot fix.
✅ Safe to Repair
- Inner rim barrel cracks (most common)
- Rim lip cracks (bead seat area)
- Hairline cracks under 2 inches in length
- Cracks running perpendicular to the lip
- Single crack (not multiple fractures)
- Face cracks on non-structural sections
❌ Not Safe to Repair
- Spoke cracks (dynamic load bearing)
- Central hub mounting face cracks
- Multiple cracks on the same wheel
- Cracks longer than 2 inches in high-stress zones
- Cracks running through structural load points
- Wheels with previous failed repairs
We inspect every wheel individually. If we cannot repair it safely, we will tell you honestly. Your safety always comes first.
Why Choose O&A Tyres For Cracked Alloy Repair?
Most tyre shops tell you a cracked wheel is scrap because they lack the specialist TIG equipment. We are one of the few workshops in Stockport with AC/DC TIG welding capability and structural repair expertise.
🔧 TIG Welding Specialist
Professional AC/DC TIG equipment with aluminium-magnesium filler rods that match OEM tensile strengths. We weld at 150+ Amps for deep, clean fusion — not surface patches.
🛡️ Safety-First Protocol
Every repair includes stop-drilling, deep V-groove preparation, dye penetrant inspection, and full pressure testing at operational PSI. We never compromise on structural safety.
⚡ Same-Day Turnaround
Emergency bookings fitted into our schedule. Most repairs are completed within 1–2 hours. Drop your wheel off and collect it ready to fit the same day.
💰 Save vs Replacement
New OEM alloy wheels cost £300–£1,000+. Our repair service starts from £50. You keep your original wheels and save hundreds of pounds.
🚗 Workshop & Mobile
We operate a professional workshop in Stockport with a dedicated welding bench. For severe cases, we can arrange wheel collection if you cannot get to us.
📋 Honest Assessment
Not every crack is repairable. We inspect and give you an honest opinion — if the wheel is unsafe to weld, we’ll tell you. No unnecessary work.
Our Structural Cracked Alloy Repair Process
A structural repair requires precision metallurgical work, not just heat. Here is the step-by-step process we follow for every cracked alloy wheel.
Dye-Penetrant Inspection
We remove the tyre, clean the wheel, and apply fluorescent dye penetrant to map the crack path, depth, and termination point with precision.
Stop-Drill & V-Groove
We drill a relief hole at the crack termination point and carve a deep V-groove along the fracture to expose clean, unoxidised aluminium.
AC TIG Fusion Weld
Using AC/DC TIG equipment, we lay structural passes from both sides using matching aluminium-magnesium filler rods for deep fusion.
Profile, Test & Balance
We machine the weld flush, pressure-test at full PSI, balance the wheel, and ensure the bead seats flawlessly.
Common Cracked Alloy Wheel Problems We Repair
Every cracked wheel is different. Here are the most common damage patterns we see across Stockport.
Pothole Impact Crack
Inner barrel cracks caused by hitting a pothole at speed. The impact stress fractures the aluminium — often invisible until the tyre deflates. We repair these structural cracks safely.
Hairline Crack Slow Puncture
Your tyre keeps losing pressure but there is no nail. This is a classic hairline crack on the inner barrel. Air escapes through the fracture under load. We weld and seal it completely.
Cracked Rim Lip
Kerb strikes or severe impact can split the rim lip. This affects the tyre bead seal and causes vibration. We weld the lip and machine it back to spec.
Severe Structural Crack
Longer cracks (over 2 inches) or multiple fractures in the barrel. Requires multi-pass welding and careful heat management to restore full strength.
Previous Poor Repair
Someone previously attempted a MIG weld or epoxy patch that failed. We grind out the bad repair, prep the metal properly, and weld it to structural standard.
⚠️ What We Cannot Repair
We do not repair spokes, the central hub mounting face, or wheels with multiple fractures in high-stress zones. We will tell you honestly if the wheel is scrap.
Who We Help With Cracked Alloy Repair
Cracked alloy wheels affect all kinds of drivers — from daily commuters to performance car owners.
Stranded Motorists
Flat tyre caused by a crack you cannot see. No spare wheel or the spare is a space-saver. We repair the crack and refit your tyre the same day so you can drive safely.
High-Performance Cars
Low-profile tyres on sports cars transmit huge impact forces. Cracks are common on 18″–22″ rims. We repair expensive OEM wheels without replacing them.
Commercial Vans & 4x4s
Heavy vehicles crack wheels under load, especially on poorly maintained roads. We repair commercial wheels and pressure test to high PSI ratings.
Enthusiasts & Classic Cars
Aftermarket or rare wheels that cannot be replaced easily. We repair them to structural spec and can arrange cosmetic refinishing after the repair.
Areas We Cover For Cracked Alloy Repair
Workshop-based in Stockport — serving all surrounding areas.
Cracked Alloy Wheel Repair — Safe, Structural, Same-Day
Alloy wheels are made from cast aluminium alloys that are strong but brittle under impact. When you hit a pothole, kerb, or debris at speed, the sudden force can fracture the metal. The result is a crack — often invisible from the outside but weeping air through the inner barrel. A cracked wheel is dangerous because the fracture can propagate and the wheel can fail catastrophically. But a professional TIG weld repair, executed correctly, restores structural integrity and saves you the cost of a new wheel.
Simply slapping epoxy or MIG welding over a crack is not a repair — it is a temporary patch that will fail under tyre pressure and heat cycling. Structural repair requires AC/DC TIG equipment, matching filler material, and a precise workflow that includes crack assessment, stop-drilling, and multi-pass welding.
TIG Welding vs MIG Welding — Why It Matters
MIG welding applies too much heat too quickly, creating a brittle, porous weld that does not fuse properly to the parent aluminium. The heat-affected zone becomes weak and prone to cracking again within weeks. TIG welding (Tungsten Inert Gas) uses a tungsten electrode to generate precise, controlled heat. The welder can adjust amperage in real time, ensuring deep penetration without overheating the surrounding metal. For alloy wheels, AC (Alternating Current) TIG welding is essential to break through the aluminium oxide layer. We use AC/DC TIG at 150+ Amps with 1.5mm–2mm aluminium-magnesium filler rods that match OEM tensile strengths — creating a weld joint that is often stronger than the original cast wheel.
What Cracks Can Be Safely Repaired?
Safe to repair: Inner rim barrel cracks (the most common), rim lip cracks, and some face cracks that are not on structural load-bearing sections. Cracks under 2 inches in length are generally straightforward. Longer cracks require multi-pass welding but are still repairable if the wheel is not extensively fatigued.
Not safe to repair: Spoke cracks, central hub mounting face cracks, multiple cracks on the same wheel, and any crack that runs through a high-stress structural point. In these cases, the wheel is structurally compromised and cannot be restored to a safe condition. We will tell you honestly if replacement is the only option — safety always comes first.
The Step-by-Step Structural Repair Process
A structural repair is not a single action — it is a sequence of precise steps. First, we remove the tyre and perform a dye penetrant test to map the crack. This reveals the exact length and direction of the fracture, including invisible micro-fractures. Second, we stop-drill the crack termination point — a relief hole that prevents the crack from propagating under thermal stress during welding. Third, we grind a deep V-groove along the crack line, removing all paint, lacquer, and oxide to expose clean aluminium. Fourth, we pre-heat the surrounding zone to prevent the alloy from acting as a massive heat sink. Fifth, we perform AC/DC TIG welding from both the inside and outside of the barrel, laying down structural passes with matching filler material. Finally, we grind the weld flush, pressure test at full PSI, and balance the wheel.
Cost Comparison — Repair vs New Wheel
A new OEM alloy wheel for most cars costs £300–£600. For premium brands (BMW, Mercedes, Audi, Porsche), a single wheel can cost £800–£1,200 or more. Aftermarket replicas may be cheaper but often have different offset and load ratings. Our repair service starts from £50 for a small crack — a fraction of the cost. You retain your original wheels, maintain your vehicle’s value, and get back on the road the same day. For wheels with multiple cracks or severe damage, we assess on a case-by-case basis and provide a transparent quote before any work begins.
After Repair — Cosmetic Refinishing Options
Welding generates localised heat that discolours or scorches the surrounding finish. If the crack is on the inner barrel, this is invisible once the tyre is fitted. If the crack extends to the outer face, we recommend a full cosmetic refurbishment after welding. We offer powder coating and diamond-cut refinishing services that restore the wheel to factory condition. Many customers opt for a full set refurbishment to ensure all wheels match perfectly.
Frequently Asked Questions — Cracked Alloy Wheel Repair Stockport
Everything you need to know about cracked alloy wheel repair, safety, and costs.
Can a cracked alloy wheel be repaired?
Yes, many cracked alloy wheels can be repaired using professional TIG welding. Cracks on the inner rim barrel and rim lip are typically repairable. Cracks on spokes or the central hub mounting face are generally not safe to repair.
Is it safe to drive on a repaired alloy wheel?
Yes, provided the repair is an AC/DC TIG weld with proper deep penetration and stop-drilling. A professionally repaired wheel is structurally sound and safe when the repair is confined to the inner barrel or rim lip.
How long does cracked alloy wheel repair take?
A standard cracked alloy wheel repair typically takes 1 to 2 hours. This includes tyre removal, metal preparation, precision TIG welding, pressure testing, and balancing.
Why is my tyre losing air if there is no puncture?
This is a classic symptom of a hairline crack on the inner barrel of your alloy wheel, usually caused by hitting a pothole. Air escapes through the fracture under the weight of the vehicle, causing a slow puncture.
How much does cracked alloy wheel repair cost in Stockport?
Hairline cracks under 1 inch start from £50. Deeper cracks (1–2 inches) on the inner barrel cost from £80. Complex or multi-pass structural repairs cost from £120. Send a photo on WhatsApp for an accurate quote.
Can you repair a cracked alloy wheel without removing the tyre?
No. The tyre must be completely removed to inspect the crack properly, stop-drill the termination point, and perform the TIG weld safely. Welding with the tyre on is dangerous and prevents proper structural penetration.
What is the difference between TIG and MIG welding for alloy wheels?
TIG (Tungsten Inert Gas) welding is the only safe method for structural alloy wheel repairs. It provides precise heat control and allows the use of matching aluminium-magnesium filler rods. MIG welding applies excessive heat and creates brittle, porous welds.
How do I know if my cracked alloy wheel is repairable?
A wheel is repairable if the crack is confined to the inner rim barrel or lip and is under 2 inches in length. We assess the location, direction, and depth using dye penetrant testing. Cracks on spokes or the hub are generally not repairable.
Is a repaired alloy wheel as strong as a new wheel?
When performed with correct AC/DC TIG technique, stop-drilling, and deep V-groove preparation, a repaired wheel can be restored to its original structural integrity — often exceeding the parent metal’s strength at the weld joint.
What causes alloy wheels to crack?
The most common cause is impact with potholes, kerbs, or debris at speed. Low-profile tyres transmit the shock directly to the wheel rim. Other causes include manufacturing defects, over-tightening of wheel nuts, and long-term metal fatigue.
Can you repair a cracked alloy wheel on the inside barrel?
Yes. Inner barrel cracks are the most common and the safest to repair because they are not visible and the structural load is well-distributed. We have full access to the inner barrel once the tyre is removed.
What is stop-drilling in wheel repair?
Stop-drilling is a technique where we drill a small relief hole precisely at the end of the crack. This prevents the crack from propagating further during the welding process due to thermal expansion. It is critical for ensuring the repair lasts.
Do you pressure test alloy wheels after repair?
Yes. Every repaired wheel undergoes a full pressure test at operational PSI (typically 30–35 PSI for cars, higher for vans). We also perform a balance check and bead-sealing test before the wheel is returned.
Is it cheaper to repair or replace a cracked alloy wheel?
Repair is significantly cheaper. A replacement OEM alloy wheel can cost £300–£1,000+ depending on the make and model. Our repair service starts from £50 for a simple crack, saving you hundreds of pounds.
Can you repair diamond-cut or polished alloy wheels?
Yes, but the diamond-cut or polished finish will be affected by the heat-affected zone around the weld. After structural repair, we recommend a professional diamond-cut or powder coating refurbishment to restore the cosmetic appearance.
How long does a repaired alloy wheel last?
A properly executed TIG weld with correct preparation and matching filler material lasts the lifetime of the wheel. The repaired area should not fail if the repair was performed to structural standards.
Can you repair alloy wheels with cracks longer than 2 inches?
We assess each crack individually. Cracks longer than 2 inches require multi-pass welding and careful heat management. In some cases, we may advise that the wheel is beyond safe repair if the crack is extensive or located in a high-stress area.
Can you repair a crack on the spoke of an alloy wheel?
No. Spokes bear the direct dynamic load and torsional stress of vehicle acceleration and braking. A crack in a spoke indicates catastrophic structural fatigue, and welding it cannot safely guarantee structural integrity. The wheel must be replaced.
Will a repaired alloy wheel pass an MOT?
Yes, a properly executed TIG weld that is ground smooth on the tyre-bead side to prevent air leaks will comfortably pass official MOT inspections. However, sloppy, rough welds with visible porosity or cracks will result in an immediate failure.
Why does a cracked rim cause a slow tyre leak?
As your vehicle travels over road imperfections, the wheel flexes slightly under the car’s weight. This tiny movement forces the crack to micro-open, allowing compressed air from the tyre cavity to escape continuously through the aluminium barrel.
Can a cracked wheel be fixed with epoxy or cold weld compounds?
Absolutely not. JB Weld, liquid epoxies, or cosmetic body fillers have zero structural tensile strength. They cannot withstand the severe structural pressures (often over 30 PSI) and constant vibrations running through a wheel, making their use incredibly dangerous.
What is the typical turnaround time for cracked alloy repair in Stockport?
For standard repairs, we aim for a 1–2 hour turnaround. We prioritise urgent repairs so you can get back on the road the same day. Contact us with your location and crack details, and we’ll book you into the next available slot.
Cracked Alloy Wheel? Get It Repaired Today.
Professional TIG welding in Stockport — structural repair, pressure tested, same-day turnaround. Save hundreds over buying a new wheel.