Rust damage on a vehicle’s wheel well can range from surface corrosion to completely rusted-through metal. The wheel well is part of the vehicle’s body and supports the weight of the vehicle. It also prevents water, dirt, and debris from getting inside the vehicle. When a wheel well gets rusted, it not only looks unsightly but can also lead to more extensive body damage if left unchecked. As such, repairing a rusted wheel well is an important maintenance task for vehicle owners. In this article, we will look at what can cause a wheel well to rust, the different levels of rust damage, how to assess the damage, and the typical costs of repairing a rusted wheel well.
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What causes a wheel well to rust?
There are several factors that can cause a vehicle’s wheel well to rust:
- Road salt – Salt used to de-ice roads in winter can get kicked up and stick to the undercarriage of a vehicle, including the wheel wells. Salt contains sodium and chloride, which accelerates the oxidation process and promotes rust formation.
- Rain and moisture – Wet conditions provide the moisture that rust needs to form. Water can collect inside the wheel wells and cause surface rust.
- Dirt and debris – Mud, dirt, sand, and gravel can get lodged inside the wheel wells, trapping moisture against the metal surface. This leads to corrosion over time.
- Damaged paint/coatings – Chipped or scratched paint exposes the bare metal underneath to moisture. This can happen from road debris striking the wheel well area.
- Previous rust damage – If rust is already present in the wheel well, it can continue to spread underneath the paint and expose more metal.
Therefore, vehicles driven year-round in cold climate regions with snow, ice, and salted roads tend to experience more wheel well rust than those driven in warmer, drier regions. But any vehicle can develop rusted wheel wells from exposure to moisture over time.
Levels of rust damage
Rust damage on a wheel well can range from minor surface corrosion to extensive rust-through of the sheet metal:
Surface rust
This early stage of rust appears as orange or brown discoloration on the wheel well surface. It is usually light surface corrosion without pitting. At this stage, the rust has not eaten through the metal and mostly involves the paint being damaged.
Pitting rust
With further untreated exposure to moisture, surface rust transitions to a pitting rust stage. Small pits and holes start developing in the metal from more extensive corrosion. There may be flaky or scaly textures but the core metal still has good integrity.
Rust-through
Over years of neglect, rust can eat entirely through the wheel well sheet metal. This leads to clean holes and loss of structural integrity. The inward side of the wheel well also becomes exposed to outside elements. Rust-through damage cannot be fixed with just surface repairs.
Assessing the damage
The extent of repairs needed depends on how far the rust has advanced on your vehicle’s wheel well. Here are some steps to assess the damage:
- Visually inspect the outward facing side of the wheel well for signs of surface rust versus pitting, holes, and flaky metal.
- Use a rubber mallet to tap along the wheel well while listening and feeling for sections that sound and feel weaker due to corrosion.
- Probe any visibly rusty areas with a awl or screwdriver to check if the metal is fragile enough to penetrate.
- Check the inner side of the wheel well (in the wheel housing) for rust-through holes or extensive corrosion.
- Assess whether the rust is isolated to small spots or widespread across most of the wheel well surface.
Use a bright flashlight and dental mirror to get the best view of the upper inner sections of the wheel well. Take photos and video of the inspected areas to document the extent of damage. The more intact and solid the core metal feels, the less extensive repairs will need to be.
Cost to repair rusted wheel wells
Repair costs vary widely based on the severity of the rust damage. Here are typical price ranges:
Surface rust repairs – $50 to $300
Light surface corrosion limited to small spots can be cleaned up and repaired with scuffing and touch-up paint for a minimal cost. This may involve:
- Sanding the area to remove loose rust
- Treating bare metal with a rust converter/primer
- Applying primer and touch-up paint
DIY repairs are possible for minor surface rust at under $50 if you already have the needed supplies. For professional repairs of multiple surface rust spots, expect to pay $200 to $300.
Pitting rust repairs – $300 to $1,000
Repairs for pitted and moderately corroded metal may involve:
- Sanding down flaky rust
- Filling pits with metal filler products
- Covering larger affected areas with fiberglass patches
- Applying primer and paint
The cost for these more extensive repairs may range from $300 for a small section needing a fiberglass patch to over $1,000 for repairs across large portions of the wheel well.
Rust-through repairs – $500 to $1,500+
For rust holes that go entirely through the sheet metal, repairs involve cutting out the damaged metal and welding in new steel replacement panels. The cost is highest for this extensive repair:
- Cut out the rusted sections
- Weld in new replacement steel panels
- Grind, seal, and apply protective undercoat
- Prime and paint job to match the vehicle
This can cost $500 to $1,500 or more depending on the shop rates and how large of a wheel well section needs replacement. Replacing entire wheel housings or quarter panels could cost up to several thousand dollars.
Preventing further rust damage
Once you’ve paid to repair a rusted wheel well, you’ll want to take measures to protect the repaired area and prevent further rust damage. Recommended prevention steps include:
- Regularly wash the undercarriage to remove dirt and road salt
- Apply rust inhibiting spray coatings
- Address any new chips/scratches in the paint right away
- Check for wet insulation/carpeting inside the wheel housing
- Keep drain holes clear to avoid moisture buildup
- Garage park the vehicle to avoid exposure to rain and snow
Maintaining thorough undercarriage cleaning and using rust prevention products after repairs are done will help maximize the life of your investment. Catching new rust early is also important before it can spread.
Professional repair vs DIY
Is it worthwhile to try DIY rust repair on wheel wells? For minor surface rust, cleaning up and touching up the spots yourself can save on cost. But extensive pitting, holes, or rust-through damage requires specialty auto body tools, materials, and skills. Unless you have professional quality tools and welding experience, extensive repairs are best left to auto body repair shops. They have the expertise to do structural repairs properly for safety and longevity.
Conclusion
Repairing a rusted wheel well before further body damage occurs is important but can also get expensive depending on the severity of the rust. Typical costs are:
- Surface rust only – $50 to $300
- Pitting rust – $300 to $1,000
- Rust-through – $500 to $1,500+
Thoroughly assessing the levels of damage and getting quotes from a few auto body shops will help you make an informed decision and budget for the needed wheel well repairs. Combining the repairs with diligent rust prevention care will then help protect your investment in that section of the vehicle body.