How to Repair Alloy Wheel Damage: A Step-by-Step Guide for OEM-Quality Results

Alloy wheels add style and performance to a vehicle, but they’re also vulnerable to damage from curbs, potholes, and generally prone to scratches. The good news? Many common alloy wheel damages can be repaired effectively, restoring them back to original.

In this guide, based on professional workshop processes, we’ll walk you through each step on how to restore wheels back to factory standards. Our guide is meant for those who are considering offering wheel repairs for customers or opening their own wheel repair business. 

These steps are based on processes used in professional wheel restoration workshops around the world, ensuring results that meet OEM standards.

Inhaltsübersicht

1. How to Restore Alloy Wheels in Three Simple Steps
2. Step 1: Prepare
3. Step 2: Repair
4. Step 3: Refinish
5. Want to Start an Alloy Wheel Repair Business?
6. Need Help with Finding the Right Equipment?

How to Restore Alloy Wheels in Three Simple Steps

PREPARE – REPAIR – REFINISH

The alloy wheel restoration process encompasses three straightforward phases: preparation, repair, and finally, refinishing. 

To achieve optimal results, it is essential to go through each of these three stages.That way you are sure to retain OEM-finish quality.

Step 1: Prepare

Remove dirt, coatings, and contaminants so the repair materials bond properly.

1. REMOVE THE WHEEL FROM THE VEHICLE

Begin på safely detaching the wheel from the vehicle to allow full access for inspection and repair.

To get better access to the wheel you can advantageously remove the tire using a tire bead breaker machine. This gives much better access when repairing drub rashes and scratches.

2. GIVE THE WHEEL A THOROUGH CLEANING

Make sure that all contaminants on the wheel are removed. Use a soft cloth to wipe off the wheel, and use a soft detailing brush to reach into spokes, lug holes, and the inner barrel to make sure that the wheel is completely free of brake dust, road grime, and hidden debris.

3. PREP THE SURFACE – SANDING AND GRINDING

Smooth and level the wheel areas to create an even foundation for repairs by sanding down curb rash, chips, and scratches using progressive grit levels, starting with 80-120 for heavy damage, then 240-320 for smoothing. The goal is to feather edges so repairs blend with the original finish.

Use a wheel blasting machine with the appropriate media size to remove old coatings and create a textured profile that ensures maximum paint adhesion.

 

It is important to be thorough in your preparation before moving on to the next step of the alloy wheel restoration process. If you still feel a scratch with your fingernail after sanding, it will show through the paint.

 

Step 2: Repair

Restore the wheel’s shape and surface so it’s structurally sound and free from defects.

4. STRAIGHTENING THE WHEEL (IF BENT)

To ensure safety, balance, and proper tire wear, restore the wheel’s shape by inspecting it for warping, flat spots, or structural deformation. Use a precision hydraulic straightening machine to correct any imperfections and verify that the wheel meets OEM tolerance before proceeding with refinishing.

Always check the wheel for structural deformations before, for example, diamond cutting, because even small dents can lead to imperfections when the wheel is placed in the Diamond Cutter.

5. DIAMOND CUTTING (IF APPLICABLE)

To recreate the signature diamond-cut appearance with exacting precision, secure the wheel in a CNC diamond-cutting lathe designed for alloy repair. Use laser-guided measurements to remove a fine layer of metal evenly, achieving a bright, reflective finish that matches original manufacturer standards.

This step is optional and only performed on specifically Diamond Cut wheels.

6. FILLING AND SURFACE RESTORATION

For chips, gouges, or deep curb rash, use an alloy-specific filler gel to restore the wheel’s original contour. Apply the filler evenly over the damaged area, slightly overfilling to allow for sanding back to a flush surface.

Once cured, shape and smooth the repair using a dual-action (DA) sander or sanding blocks, starting with coarse grit and progressing to finer grit for a seamless finish. This ensures the wheel is structurally sound and perfectly smooth before moving on to refinishing.

Notice that alloy-specific fillers often need mixing (if two-part) and have a working time before curing.

 

Before moving on to refinishing, make sure the wheel’s shape and surface are completely restored. Any remaining dents, low spots, or rough patches will be highlighed by primer and paint – so it’s worth taking the extra time now to get it perfect. 

 

Step 3: Refinish

Apply coatings and protective layers to achieve a durable, factory-quality finish.

7. PAINTING (OEM MATCH OR CUSTOM COLOR)

To achieve a flawless finish, use premium alloy-specific paints for enhanced adhesion and durability. Refresh the wheel’s appearance with OEM colors or custom finishes. Start with an adhesion-promoting primer, apply base coats evenly, and finish with a clear coat. Maintain proper flash times between coats to avoid imperfections.

To get those consistent, dust-free results, many pro workshops rely on fully automatic wheel paint machines. They help make sure the paint goes on evenly and cuts down on waste.

8. NANO PROTECTION COATING

Apply an advanced nano-ceramic coating to alloy wheels to create a surface that repels water, brake dust, and dirt. This will enhance longevity and minimize cleaning efforts.

The coating has a lifespan of 6-12 months depending on driving conditions.

9. BALANCING AND REMOUNTING

Finalize the repair by ensuring optimal driving performance. Use a dynamic wheel balancer to eliminate vibration and uneven rotation. Make sure to check your tire pressure and tighten the wheel nuts according to the manufacturer’s specs. This helps avoid vibrations, uneven wear, and any safety problems down the line.

Finally, mount the wheel back onto the vehicle and perform a final quality check.

Want to Start an Alloy Wheel Repair Business?

Repairing alloy wheel damage is a manageable task and a smart move in today’s automotive industry.

By following the structured process of preparation, repair, and refinishing, you can offer alloy wheel repairs to your customers.

Wheel Restore is ready to help you launch your wheel repair business. We provide everything you need, including professional-grade machines, complete equipments packages, expert training, OEM-certified paint systems, and flexible Finanzierungsmöglichkeiten tailored to your budget.

Need Help with Finding the Right Equipment?

If you’re unsure which machines and equipment you need to get started, our dedicated sales team can design a wheel repair setup tailored to your business.

Kontaktieren Sie uns heute and let us help you get started.