Vehicle Rust Repair Ireland
From bubbling sills to holes in the floor pan, we cut corrosion out and weld in fresh metal — then seal and coat it so it does not come back through.
In short
- Rust repair replaces corroded metal with new steel; it is not a filler or paint job.
- Common repair areas are sills, floor pans, inner wings, arches, chassis rails and box sections.
- Every repair is sealed, primed, painted and coated to stop moisture reaching the new steel.
- Send WhatsApp photos of the affected area to 087 919 2193 and we'll tell you honestly whether it's a repair worth doing before you travel to the yard.
Why Irish vehicles rust the way they do
Ireland gives steel the worst of both worlds: constant damp for most of the year and salted roads through winter. Add coastal air on the west and south coasts and corrosion moves faster here than in most of Europe.
Rust nearly always starts where water can sit and not drain — inside box sections, behind wheel arch liners, in seams, under old flaking underseal and around anywhere the factory coating was broken by a stone or a tow-bar bolt.
What we repair
- Sills, inner sills and jacking points
- Floor pans and footwells
- Wheel arches and rear quarters
- Inner wings and turret tops
- Chassis rails, outriggers and crossmembers
- Boot floors and spare wheel wells
- Door bottoms and skins
- Suspension and subframe mounting areas
Repair versus cover-up
Plenty of rust 'repairs' are filler, mesh and a coat of stone chip. It looks fine for a season and then bubbles again — usually worse, because the filler holds moisture against the panel.
Our approach is simple: if metal has gone, metal goes back. We cut past the corrosion into clean steel, fabricate a patch or section to fit, weld it, dress it, seal the seams and coat it.
After the welding
Rust repair and rust prevention belong together. Once the welding is done we treat the surrounding area, seal the joints and apply underbody protection so the repaired section is not the next place water gets in. If you want the whole underside protected at the same time, that is usually the cheapest time to do it.
Every repair, step by step
- Vehicle on the ramp — full underbody assessment and photos
- Corroded steel cut back to clean, solid metal
- Repair sections fabricated from correct-gauge steel
- MIG welded, dressed back and checked for full penetration
- Seams sealed to keep water out of the joint
- Primed and painted before any coating goes on
- Underbody protection applied over the finished repair
- Photos of the work sent to you before collection
Real welding & rust repair work
Every photo is real work carried out at Rayco — no stock images.
Frequently asked questions
Is rust repair worth doing?
If the corrosion is localised and the rest of the vehicle is sound, yes — welding in new steel is usually far cheaper than replacing the vehicle. We'll tell you if we think it isn't worth the spend.
Can you repair rust without welding?
Not properly. Where metal has perforated, the only lasting fix is to cut it out and weld new steel in. Filler and mesh trap moisture and the rust returns.
Will the rust come back after repair?
Not in the repaired section if it is welded, sealed, primed, painted and coated correctly. Rust can still start elsewhere on the vehicle, which is why underbody protection matters.
Do you repair rust that failed the NCT?
Yes — corrosion failures are one of the most common jobs we do. Bring or send the fail sheet and we'll work to what the tester marked.
How do I get a price?
WhatsApp clear photos of the rust to 087 919 2193, ideally with the vehicle year, make and model. We'll come back with an honest range.
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.