Rust Hole Repair Ireland
Once rust has made a hole, filler is a waste of money. We cut the hole and the thin metal around it out, weld in new steel, then seal and coat it.
In short
- A visible rust hole almost always means the surrounding metal is already thin, so the repair area is bigger than the hole.
- The only lasting fix is to cut back to sound steel and weld in a new section of the correct gauge.
- Filler, mesh and stone chip over a hole traps moisture and the corrosion returns worse.
- Send WhatsApp photos of the underside to 087 919 2193 and we'll tell you honestly what the vehicle needs before you travel to the yard.
Where rust holes usually appear
- Sills, inner sills and jacking points
- Floor pans and footwells
- Wheel arches and rear quarters
- Chassis rails and box sections
- Boot floors and spare wheel wells
- Door bottoms and rear valances
Why we don't fill rust holes
Filler and glass fibre sit on top of corroded steel and hold moisture against it. The patch looks fine for a season, then bubbles again — and by then the sound metal you could have welded to has gone too.
Welding costs more on the day and less over the life of the vehicle. It is also the only version that stands up to an NCT corrosion inspection on a structural area.
How the repair is done
The area is cleaned back so we can see how far the corrosion actually runs. We cut past it into clean steel, fabricate a patch to match the original profile, MIG weld it in and dress the welds back.
The joint is then seam-sealed, primed, painted and coated with underbody protection so water cannot reach the new metal from either side.
Every repair, step by step
- Ramp inspection with photos of every affected area
- Corroded steel cut back to clean, solid metal
- Repair sections fabricated in correct-gauge steel
- MIG welded for full penetration and dressed back
- Seams sealed so water cannot enter the joint
- Primed and painted before coating
- Underbody protection applied over the repair
- Photos of the finished work before collection
Real welding & rust repair work
Every photo is real work carried out at Rayco — no stock images.
Frequently asked questions
Can a rust hole be repaired without welding?
Not properly. Where metal has perforated, the only lasting fix is to cut it out and weld new steel in. Filler holds moisture and the rust comes back.
How much does rust hole repair cost?
It depends on how big the affected area is once the thin metal around the hole is cut back. Send WhatsApp photos to 087 919 2193 for an honest range.
Will it pass the NCT?
A hole repaired with correct-gauge steel, full-penetration welds and proper sealing is done to the standard the test looks for. We repair corrosion failures regularly.
Is one hole a sign of more rust?
Usually, yes. Rust rots steel from the inside out, so a hole on the outside means the surrounding metal is already thin. We check the whole underside on the ramp.
Related chassis & welding services
Get a welding quote today
WhatsApp photos of the rust or damage — or the NCT fail sheet — and we'll come back with an honest price before you travel.