Cracked Aluminum Alloy Wheels: Why Professional Repair Matters
Aluminum alloy wheels can crack if they’re hit hard enough. How much force it takes depends on factors like the brittleness of the alloy, the wheel design, and the tire’s aspect ratio. A deep pothole or a raised manhole cover is often enough to do the damage.
Cracks aren’t just dangerous because they can leak air—they can fail suddenly and without warning, creating a major safety risk.
Hidden Cracks = Hidden Danger
At Houston Wheel Repair, we often see wheels with small cracks hidden under the tire bead, which may not leak right away. Many customers are surprised to learn that even these “sealed” cracks need to be repaired. Left untreated, cracks almost always grow—and often take less force to expand than it took to cause the original damage.
If a crack spreads, turns, or splits, there’s a real risk of losing an entire piece of the wheel catastrophically.
Key Considerations in Welding Cracked Wheels
✅ Crack Location & Direction
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Most cracks on the back side cross the flange and bead area at a right angle to the spin. These can usually be opened and properly welded.
✅ Welding Technique
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Aluminum wheels must be TIG welded.
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MIG welding is a disaster for wheels—it weakens the surrounding alloy and leaves a thin, fragile weld.
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Only a trained, experienced TIG welder should repair wheels.
✅ Pre-Welding Straightening
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Any impact strong enough to crack a wheel usually bends it, too.
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Wheels should be straightened before welding to avoid stressing and breaking the weld later.
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Even after welding, slight warping can occur from the heat and may require minor truing.
Finishing the Weld
After welding, the weld bead must be perfectly smoothed, especially where the tire seals. Imperfect finishing can lead to air leaks.
Some shops cut corners, grinding only the visible side or rushing the job. At Houston Wheel Repair, we take the extra 20–30 minutes per wheel to smooth both the inside and outside of the barrel. The result is a clean, reliable repair that looks great and performs like it should.
Why Choose Us?
Welding a cracked wheel is not something to leave to amateurs. At Houston Wheel Repair, our technicians have over 22 years of combined TIG welding experience. We’ve repaired thousands of wheels for drivers across the Houston area—and we’re the trusted welding service for over 50% of local wheel and tire shops.
Cut out the middleman and bring your wheel straight to the source to save time and money.
✅ Same-Day Service Available
✅ While-You-Wait Repairs Offered
