Rear spring hangers & shackle mounts
The single most common NCT welding failure we see. Mud sits in the hanger, the plate thins from the inside, and it usually looks fine from below until it's probed.
Chassis Welding & Repair Specialists — Ireland
Chassis Welding & Repair Ireland
Rusted chassis rails, broken outriggers, rotten sills, failed NCT? Rayco cut out the rot, weld in fresh metal to NCT standard, and seal it for years. Cars, 4x4s, vans and commercials.
Chassis Welding Specialists
What we weld & repair
No quick fixes, no glass fibre over rust. Every weld is full-penetration MIG, treated, painted and sealed so the repair lasts longer than the original metal did.
- Chassis rails & main frame welding
- Outrigger replacement (Defender, Discovery, Hilux)
- Crossmember & body-mount repair
- Sill, floor pan & inner wing welding
- Rust cut-out & fresh metal fabrication
- NCT failure welding to test standard
- Full rust treatment & underseal after welding
- 4x4, van, jeep and commercial chassis work
Where it fails
Where Irish chassis rot first
Salted roads from October to March, damp coastal air the rest of the year and mud packed into box sections — these are the four areas we cut out and weld most often on Irish vehicles.
Outriggers and body mounts
Defender, Discovery and older 4x4 outriggers rot where the outrigger meets the rail. We replace with correct-gauge sections rather than plating over a soft mount.
Chassis rail ahead of the rear axle
Salt spray is thrown straight into this section all winter. It's a structural area, so the NCT treats perforation here seriously — and it's very repairable if caught early.
Sills, jacking points and inner floor
Vans and cars fail on sill and jacking-point corrosion more than anything else. Rot is cut out to clean metal and fresh steel welded in, never filled.
Step by step
From NCT fail to sealed repair
- 1
Send photos
WhatsApp the rusted areas and your NCT report. Honest same-day read on whether it's a weld job or a seal job.
- 2
Ramp inspection
Vehicle up in Wexford and the structure probed properly, so the quote reflects what's actually there.
- 3
Cut back to sound steel
Rot removed until only clean metal is left. No plating over soft or flaking sections.
- 4
Weld to NCT standard
Full-penetration MIG in the correct gauge steel, seams dressed and checked.
- 5
Treat, paint and seal
Bare weld zinc-primed, painted and undersealed; cavity wax injected into enclosed box sections.
- 6
Photos and retest
Finished repair photographed and sent to you, ready to go straight back for the NCT retest.
Not sure whether it needs welding or just sealing? Book a free chassis check or read about NCT rust repair.
Real chassis welding work
Every photo is real Rayco work — no stock images.
Vehicle-Specific Chassis Pages
Specialist chassis work by vehicle
Land Cruiser ChassisHilux Chassis RepairDefender Chassis WeldingLand Rover ChassisFord Ranger ChassisJeep ChassisCommercial / Van ChassisNCT Rust & Welding Repair
Chassis welding by vehicle type
Car Chassis Welding IrelandJeep Chassis Welding Ireland4x4 Chassis Welding IrelandPickup Chassis Welding IrelandVan Chassis Welding IrelandCommercial Vehicle Chassis Repair IrelandTrailer Chassis Repairs IrelandPlant Machinery Welding IrelandAgricultural Machinery Welding IrelandAgricultural Vehicle Chassis Repair
Related welding & rust repair services
Chassis Repair IrelandVehicle Rust Repair IrelandStructural Welding Repairs IrelandRusted Chassis Repair IrelandCorrosion Repair IrelandChassis Restoration IrelandWelding Repairs IrelandFabrication & Welding Repairs IrelandUnderbody Corrosion Repair IrelandChassis Welding Near MeStructural Vehicle Repairs Ireland
Chassis welding by county
We take chassis welding work from all 32 counties.
Our workshop is in County Wexford — chassis welding Wexford.
Chassis Welding WexfordChassis Welding WicklowChassis Welding CarlowChassis Welding KilkennyChassis Welding WaterfordChassis Welding DublinChassis Welding KildareChassis Welding MeathChassis Welding LouthChassis Welding CorkChassis Welding KerryChassis Welding LimerickChassis Welding ClareChassis Welding TipperaryChassis Welding GalwayChassis Welding MayoChassis Welding SligoChassis Welding LeitrimChassis Welding RoscommonChassis Welding DonegalChassis Welding MonaghanChassis Welding CavanChassis Welding LongfordChassis Welding WestmeathChassis Welding OffalyChassis Welding LaoisChassis Welding AntrimChassis Welding ArmaghChassis Welding DownChassis Welding FermanaghChassis Welding TyroneChassis Welding Derry
FAQs
Chassis welding questions
Do you do chassis welding in Ireland?
Yes — chassis welding is core to what Rayco do. Outriggers, chassis rails, sills, crossmembers, body mounts and rusted floor sections on cars, 4x4s, vans and commercials.
How much does chassis welding cost in Ireland?
Chassis welding is quoted individually depending on how much rusted metal has to be cut out and replaced, and whether outriggers or crossmembers are involved. WhatsApp chassis photos for an honest quote.
Will welding the chassis pass the NCT?
Yes — provided the repair is done properly with the right gauge metal, full-penetration MIG welds and treated for rust. We weld to NCT standard and underseal afterwards so it stays sealed for years.
Do you repair Land Cruiser, Hilux, Defender and Ranger chassis?
Yes — Land Cruiser, Hilux, Defender, Discovery, Range Rover, Ranger, Navara and L200 chassis welding is something we do every week. We carry specific repair sections for the common rust points.
Do you underseal after welding?
Always. Welded metal is bare and will rust again fast if left exposed. We treat, paint and apply premium underseal over every welded section before the vehicle leaves.
How long does chassis welding take?
Most jobs are 1–3 days depending on how much rust has to come out. Bigger 4x4 jobs with multiple outriggers can take up to a week. We give you a clear timeline before you book in.
Where do Irish chassis normally rot first?
Rear spring hangers, outriggers, body-mount pads, the rail section just ahead of the back axle, and anywhere a bracket traps mud. On Irish vehicles it's nearly always the sections that stay wet — road salt gets in, mud packs behind it and holds it there for months.
Can a rotten chassis be repaired or does it need replacing?
Most can be repaired. Full chassis replacement is only worth it when rot runs the length of both rails. We cut back to sound steel and plate or section it with the correct gauge — if a vehicle is genuinely beyond economical repair, we tell you that instead of taking the job.
Do you weld galvanised and box-section chassis?
Yes. Galvanised coating is ground back at the weld area and the repair is zinc-primed afterwards, otherwise the weld corrodes faster than the metal around it. Enclosed box sections get cavity wax injected once the welding is finished.
Can I get a chassis welding quote before travelling?
Yes — WhatsApp photos of the rusted areas and your NCT report if you have one. We come back the same day with an honest read, so nobody drives to Wexford for a job that turns out different on the ramp.
Get a Chassis Welding Quote
Send WhatsApp photos of the rust or NCT report and we'll quote before you visit.