How to Fix a Cracked Rim Without Welding (DIY Epoxy Method)

No matter how cautiously you navigate or how smooth the roads are, your car’s rim is bound to get damaged eventually. When that happens, how can you repair a cracked rim?

The typical response might be, “I’ll bring the rim to my mechanic for TIG or MIG welding.”

However, there’s a more effective and simpler method to mend a cracked rim without welding.

In this article, my goal is to guide you through using an epoxy method to seal a crack in a car rim. Let’s dive into the process together.

How to Repair a Cracked Rim Without Welding

The rim is a vital part of your vehicle, safeguarding the tire and ensuring a safe, comfortable ride. Whether made of alloy, steel, chrome, or a spinner design, rims can crack unexpectedly. This often results from rough driving habits or tough road conditions, such as striking curbs, hitting potholes, driving on flat tires, or traveling on uneven surfaces.

A cracked rim can lead to air leaks, as it fails to hold air properly. If not addressed promptly, the damaged rim may not seal the tire bead, weakening the wheel system’s structural stability.

Step-by-Step Guide to Repair a Cracked Rim

Tools and materials required:

• JB epoxy
• Clean cloth
• Wire brush
• 180-grit sandpaper
• Resin tube
• Tire iron
• Hardener tube
• Wheel chocks
• Torque wrench
• Jack stands

Step 1: Park and Examine the Wheel

Park your vehicle on a flat, secure surface. Start by visually inspecting the wheel. For a thorough check, you may need to remove the wheel assembly to access the rim. If the crack isn’t immediately visible, use a wire brush to clean a few inches of the rim’s surface to help locate the damaged area.

Step 2: Use Rubbing Alcohol

After identifying and cleaning the cracked area, dampen a clean cloth with rubbing alcohol. Wipe the cracked section and a bit of the surrounding area. Let the alcohol dry completely on the surface.

Step 3: Mix and Apply JB Epoxy

Combine equal parts of resin and hardener. Pour the hardener into the resin container and mix thoroughly with a stirrer until the color is uniform. This ensures the epoxy is well-blended.

Spread the epoxy over the cracked area using a flat scraper. Gently press the mixture into the crack, ensuring it covers 1–2 inches around the damage. Smooth the epoxy with the scraper to help it penetrate the crack.

Step 4: Let the Epoxy Dry

Allow the epoxy to cure for several hours, ideally overnight, to bond firmly with the rim. Avoid using artificial drying methods like a hairdryer; let it dry naturally to harden properly.

Step 5: Reinstall the Rim

After 24 hours, inspect the repaired crack to confirm the epoxy has bonded well. If it has, reattach the rim to the vehicle’s wheel, following proper reinstallation steps.

Step 6: Check the Repair

With the rim repaired, evaluate the quality of your work. Ensure the fix meets your expectations for time and effort. If done correctly, the rim should be restored to full functionality. Test it by driving short distances.

FAQs

Is Driving on a Cracked Rim Safe?

Driving on a cracked rim is risky. The crack could worsen, causing the wheel to deform. Over time, the rim may break apart completely.

Even if the crack doesn’t spread immediately, there’s no guarantee of safety as the vehicle ages or weather conditions change.

Should I Fix or Replace a Cracked Rim?

A small crack on the inner or middle part of the rim can often be repaired. However, a large crack on the outer edge that spreads in multiple directions poses a safety hazard and weakens the wheel’s structure.

In such cases, replacement is necessary. Steel rims are generally safer and cheaper to repair than aluminum, alloy, or chrome rims. Avoid repairing cracked aluminum rims.

Is Repairing or Replacing a Cracked Rim Better?

Some rim cracks are beyond repair, leaving replacement as the only option. If the crack is unfixable, you’ll need to replace the rim, regardless of cost.

A DIY epoxy repair might cost $300–$400. Professional repairs typically range from $100–$200, depending on the crack’s severity, your location, and the rim’s size.

Final Thoughts

In closing, replacing a damaged rim may be the most reliable long-term solution. However, budget constraints can make repairs a practical choice. If you choose to repair, the epoxy method I’ve outlined can be more durable and safer than welding, keeping your rim roadworthy.

I hope this guide empowers you to save money or become a confident DIY rim repairer.