If your car has failed its MOT because of corrosion, or you’ve noticed rust bubbling around the sills, arches or floor pan, the first question is always the same: how much is car welding going to cost me?
The honest answer is “it depends” — but that’s not very useful when you’re trying to budget for a repair. As a local, MOT-focused welding and fabrication workshop based in Lye, Stourbridge, we get asked about pricing every single day. So in this guide, we’re breaking down real 2026 UK price ranges for the most common car welding jobs, what actually drives the cost up or down, and how to avoid paying over the odds for a repair your car doesn’t even need.
Whether you’re dealing with a structural MOT failure, a cracked alloy, or you just want to plan ahead before rust becomes a bigger problem, this guide will give you a realistic picture of what to expect.
What Affects the Cost of Car Welding in Stourbridge?
No two welding jobs are identical, even when they sound similar on paper. A handful of factors decide whether a repair costs £80 or £800:
- Type of repair – A small patch weld on an exhaust bracket is nothing like a full sill replacement or structural chassis repair.
- Extent of the corrosion – Surface rust is cheap to sort. Rust that’s eaten through structural steel usually means cutting out and replacing sections of metal, which takes longer and costs more.
- Material – Standard steel bodywork is more straightforward than aluminium welding, which needs specialist TIG equipment and more skill.
- Access and vehicle design – Some cars have sills, arches or chassis rails that are easy to reach. Others need panels stripped back first, which adds labour time.
- MOT deadline pressure – If your car needs to pass a retest in a few days, that urgency can occasionally affect scheduling, though it shouldn’t affect the quality of the weld.
- Whether it’s a patch repair or full replacement – Patching a small hole is far cheaper than replacing an entire structural panel.
- Paint and finishing – A weld repair that also needs re-painting or underseal will cost more than a bare metal repair on a part that won’t be seen.
Understanding these variables is the difference between getting a fair quote and being caught out.
Average Car Welding Prices in Stourbridge (2026)
Below are typical UK price ranges based on the kind of jobs we handle regularly. These are guide prices only — every car is different, and the only way to get an accurate figure is a proper inspection and quote.
| Repair Type | Typical Price Range (2026) |
|---|---|
| Small patch weld (exhaust bracket, small hole) | £60 – £150 |
| Sill repair (partial) | £150 – £350 |
| Full sill replacement (per side) | £300 – £600 |
| Wheel arch repair | £120 – £300 |
| Floor pan repair | £150 – £450 |
| Chassis leg / structural repair | £250 – £800+ |
| Alloy wheel crack repair | £40 – £90 per wheel |
| Body panel replacement | £200 – £600 |
| Aluminium chassis/panel welding | £250 – £700+ |
| Camper van chassis/body welding | £300 – £900+ |
Jobs involving heavy corrosion, multiple panels, or full body panel replacement will naturally sit at the higher end. If you’re only dealing with one small area, you’re far more likely to be looking at the lower end of these ranges.
Why MOT Corrosion Repairs Cost What They Do
A large chunk of the car welding work we do in Stourbridge is directly related to MOT failures. Corrosion on structural areas — sills, chassis legs, seatbelt mounting points, and suspension mounting areas — is treated seriously by MOT testers because it affects the safety of the vehicle.
The cost of an MOT-related weld repair usually comes down to how much metal has to be cut out and replaced, not just how big the rust patch looks from the outside. Rust often spreads further under the surface than it appears, which is why a “small” repair can sometimes turn into something bigger once the affected panel is opened up. We’ve written a detailed breakdown of why cars fail their MOT on corrosion if you want to understand exactly what testers are looking for, and we’ve also put together a pre-MOT structural rust checklist so you can check your own car before booking a test.
MIG vs TIG Welding: Does It Change the Price?
Yes, to some degree. MIG welding is the standard method for most steel bodywork repairs — sills, arches, floor pans, and general structural steel. It’s efficient, strong, and cost-effective for the majority of car welding jobs, which is why it’s used on most MIG welding services in Stourbridge.
TIG welding is slower, more precise, and required for aluminium, thinner metals, and jobs where a cleaner, stronger finish matters — think aluminium chassis components, camper van panels, or motorsport fabrication. Because TIG welding takes more time and skill to execute properly, it’s generally priced slightly higher per hour than MIG work.
If a garage has quoted you a flat “welding cost” without specifying MIG or TIG, it’s worth asking which process your repair actually needs — using the wrong one isn’t just a pricing issue, it can affect the strength and longevity of the repair.
Aluminium & Specialist Vehicle Welding Costs
Aluminium bodywork and chassis components (common on newer vehicles, performance cars, and some vans) require specialist equipment and experience. Aluminium welding typically costs more than equivalent steel work because the metal behaves very differently under heat and needs a controlled, contamination-free environment.
Similarly, camper van welding — particularly chassis and box-section repairs — often costs more than a standard car repair simply because of the size of the vehicle and the amount of metal involved.
If you’ve got a cracked or kerbed alloy wheel rather than a full welding job, that’s usually a much smaller cost. Alloy wheel crack repair is one of the more affordable services we offer, and it’s often far cheaper than replacing the wheel entirely.
Structural & Chassis Repair Costs
Chassis and structural welding sits at the top end of the pricing scale, and for good reason — this is safety-critical work. A chassis repair has to be strong enough to pass MOT inspection and hold up under real driving conditions, which means using the correct grade of steel, proper preparation, and a welder who understands structural loading, not just how to run a bead.
We cover the full range of structural repair work for vehicles across Stourbridge and the wider West Midlands, and pricing here is always based on a physical inspection rather than a phone estimate — the difference between a straightforward repair and one that needs extensive metal replacement can be significant.
Hidden Costs to Watch Out For
A few things catch car owners out when budgeting for welding repairs:
- Rust that spreads further than expected once panels are opened up
- Underseal and cavity wax needed after the repair to prevent future corrosion
- Paint matching if the repair is on a visible panel
- Retest fees if the repair is booked separately from the MOT retest
- Additional structural points discovered during inspection that weren’t part of the original quote
A good workshop will always flag these possibilities before starting work, not after. We’ve listed some of the less obvious warning signs in our guide to 10 hidden signs your car needs welding — spotting these early usually means a smaller, cheaper repair.
How to Choose the Right Car Welder (Without Overpaying)
Price shouldn’t be the only factor, but it’s a fair question to ask alongside a few others:
- Do they specialise in automotive welding, or is it a general fabrication sideline?
- Can they show examples of previous MOT-related structural repairs?
- Do they explain what’s being replaced and why, rather than just quoting a number?
- Are they using the right process (MIG vs TIG) for your specific repair?
- Do they offer a written quote after inspecting the car, not just a phone estimate?
We’ve put together a more detailed breakdown in our guide on how to choose the right car welder, which covers exactly what to look for before booking any repair.
DIY vs Professional Welding: Is It Worth the Risk?
It might be tempting to save money with a DIY MIG welder from a home fabrication kit, especially for a small patch. But structural car welding is not the place to cut corners. An MOT tester will fail a poor-quality weld just as quickly as untreated rust, and a repair that isn’t strong enough can genuinely affect the safety of the vehicle in a collision. What looks like a saving upfront often turns into a repeat cost once it’s rejected at MOT or needs redoing properly.
Common Car Welding Repairs and Their Price Range
For a broader look at the most frequent jobs we see — beyond just cost — our guide to the 5 most common car welding repairs walks through sills, arches, floor pans, exhausts and chassis work in more detail, including what causes each one and how long they typically take.
Areas We Cover Around Stourbridge
We carry out car welding for customers across Stourbridge and the surrounding West Midlands and Worcestershire areas, including Lye, Halesowen, Dudley, Kingswinford, Wolverhampton, Birmingham, Solihull, Bromsgrove and Redditch. You can see our full car welding near Stourbridge coverage, along with our wider West Midlands locations page.
Why Choose MJ Welding & Fabrication
We’re a Stourbridge-based welding and fabrication workshop specialising in automotive repair — MIG and TIG welding, structural and chassis work, alloy wheel crack repair, sills and arches, aluminium welding, and MOT corrosion repairs. Every quote is based on a proper inspection, not a guess over the phone, so you know exactly what you’re paying for before any work starts. You can read more about our workshop and experience on our About Us page, or see the full range of services we offer.
Frequently Asked Questions
Is car welding expensive in the UK?
It depends entirely on the job. A small patch repair can be under £100, while a full structural or chassis repair can run into several hundred pounds. Getting an inspection first is the only way to get an accurate figure.
Can I get an exact price without bringing my car in?
Not reliably. Corrosion often hides more damage than what’s visible on the surface, so accurate quotes are always based on a physical inspection.
Does welding always mean my car has failed its MOT?
No. Plenty of our customers come to us proactively, before a rust patch becomes a structural MOT failure. Catching it early is almost always cheaper.
How long does a typical car welding repair take?
A small patch repair can be done same day. Larger structural jobs like sill or chassis replacement usually take one to three days, depending on parts and extent of the work.
Do you offer a warranty on welding repairs?
Yes, our repairs are carried out to MOT-safe structural standards. Get in touch for specific details relevant to your repair.
Is TIG welding always more expensive than MIG?
Generally yes, because it’s slower and more precise. But it’s also the correct method for aluminium and certain thin or delicate metals, so it isn’t a case of one being “better” — it’s about using the right process for the material.
Get a Free, No-Obligation Welding Quote in Stourbridge
If your car has failed its MOT on corrosion, or you’ve spotted rust starting to take hold, don’t wait for it to get worse. Contact MJ Welding & Fabrication today for an honest inspection and a clear, upfront quote — no guesswork, no inflated pricing, just an accurate picture of what your repair actually needs.
📞 Call: +44 7532 794934 📍 Bromley St, Lye, Stourbridge DY9 8HU
