How Much Does Car Rust Repair Cost?

Rust on your car can range from a minor cosmetic issue to a structural hazard that may fail your MOT. Whether it's surface rust on a wheel arch or penetrating rust in the boot floor, repair costs can vary dramatically depending on labour, severity, and vehicle model. Minor fixes might cost as little as £175, while extensive repairs involving panel replacement or welding could rise above £3,000. This guide explores common rust types, repair methods, pricing variables, and when DIY rust repair is realistic. You'll also find links to professional bodywork repair services, products, and expert rust solutions from Sprayshack Ltd, a UK specialist in vehicle restoration and refinishing.

What Actually Determines the Cost of Car Rust Repair?

When people ask, “how much does it cost to fix rust on a car?”, they often expect a simple answer. But rust repair isn’t one-size-fits-all. It can range from a quick touch-up to a full corrosion repair job depending on several factors:

Key Variables That Affect Rust Repair Cost:

• Extent of the rust: Is it surface rust or penetrating rust?

• Location of the rust: Wheel arches, sills, boot floor, or suspension components?

• Age and model of the vehicle: Older cars are more susceptible due to oxidation and paint degradation.

• Labour intensity: Time-consuming jobs like welding or sandblasting raise the overall bill.

• Finish quality: Are you blending in the new paintwork, or going for a full respray?

"What looks like a simple spot could be hiding hidden rust damage behind the panel. The true cost is often revealed after a professional inspection."

That’s why we always recommend starting with a vehicle inspection for rust before budgeting anything.

Common Rust Areas (And What You Might Pay)

Rust rarely stays in one place. Once it begins, it spreads, especially in damp UK conditions. Below are some of the most affected areas, along with average pricing and repair methods.

1. Wheel Arch Rust

Arguably the UK's most notorious rust zone, wheel arch rust is a silent destroyer. It often begins on the inside where moisture and salt exposure mix with grime to slowly degrade the metal.

• Estimated cost: £300–£2,000 per arch

• Typical treatment: Rust cut-out, new metal welded, resprayed, and sealed

• Preventive tip: Regular cleaning and reapplying underseal can significantly delay rusting

Looking for an expert finish? See our insurance-approved repair work that includes rust restoration and paint matching.

2. Sills and Structural Components

The sills support your car's rigidity. If they rust, not only is it dangerous—it can fail an MOT.

• Estimated cost: £400–£1,500+

• Repair approach: Often requires complete sill panel replacement and structural welds

• Watch for: Damp footwells, bubbling paint near the door base, or visible flaking

For vehicles needing structural integrity restored to factory spec, our team specialises in bodywork repair for both modern and classic cars.

Is It Just Cosmetic, or Something More?

Don’t be fooled by what appears to be a bit of flaking paint. Rust often originates where you can’t see it. The three main types of rust are:

• Surface Rust

• Appears as rust blisters, often following a scratch or stone chip

• Usually confined to the paint layer and upper metal

• Ideal for DIY rust repair or professional sanding + sealing

• Scale Rust

• Grows deeper into the metal, creating pitting and rough texture

• Requires metal filler for rust or mechanical abrasion before repaint

• Penetrating Rust

• The worst-case scenario; actual holes in the metal

• Needs cut-out sections, welding, and potential panel replacement

Have early signs of bubbling paint or flakes? Book in for professional rust treatment before it becomes a costly restoration job.

DIY vs. Professional Rust Repair: What’s Worth It?

There’s a common temptation to grab some wire wool, a spray can, and sort rust yourself. For surface rust, that might be enough. But anything beyond that is best left to professionals—especially if you want the repair to last longer than a season.

When DIY Rust Repair Makes Sense:

• Very minor surface rust

• Small spots where paint bubbling under paint has just begun

• You already own or are willing to buy tools like rust converter paint, metal filler, and sandpaper

“DIY fixes can be surprisingly effective for small rust patches, but keep in mind that without the right tools and technique, you could be sealing in the problem rather than solving it.”

When to Call in the Experts:

• Any signs of penetrating rust

• Rust near structural components like suspension mounts, subframes, or sills

• You're dealing with repeat issues (previous patch-up jobs didn’t hold)

• Your car is up for MOT, and you're unsure what lies beneath

If you're considering professional help, don't just take our word for it — hear from customers who’ve trusted us with long-term rust prevention in their testimonials on our feedback page.

What Does Professional Rust Repair Really Involve?

Unlike a cosmetic touch-up, full-scale rust repair is a multi-step, technical process. Here's a breakdown of what often goes into it:

Standard Rust Removal Procedure:

1. Vehicle inspection for rust

   • Checking for visible and hidden rust damage

2. Sandblasting or mechanical prep

   • Removing oxidised metal without damaging the surrounding area

3. Localized rust removal

   • Cutting out decayed sections if needed

4. Welding in new metal or using metal filler for rust

5. Sealing with primer, cavity wax, and clear coat protection

6. Respraying or blending the paint to match the original finish

Depending on the size of the affected area, this process can take from a few hours to several days. Larger jobs may involve removing panels or even stripping back the underbody for full rustproofing.

Want to see how this looks in action? Take a peek at our detailed before-and-after rust repair examples on our work portfolio.

What Kind of Rust Costs the Most?

Here’s a quick breakdown of estimated rust repair costs by type and location, based on market averages and what we see in our garage regularly:

Rust Area	Estimated Cost (UK)	Typical Treatment
Surface rust	£150 – £400	Sanding, primer, repaint
Wheel arch rust	£300 – £2,000 per side	Panel repair, welding, respray
Sills rust	£400 – £1,500+	Cut and weld, structural reinforcement
Boot floor rust	£250 – £800	Remove & replace corroded floor sections
Suspension rust	£125 – £500	Replace rusted arms/springs, repaint
Exhaust rust	£175 – £500	Replacement pipe, underbody protection

Costs vary based on labour, parts, and the level of finishing you choose. For instance, you may opt for a respray or full panel replacement, which pushes prices higher.

If your car has existing cosmetic damage or faded areas, rust can be fixed as part of larger repairs — including insurance-approved bodywork services that might help offset your costs.

How to Prevent Rust from Coming Back

Fixing rust is one thing — keeping it gone is another. Prevention plays a key role in long-term vehicle value and safety.

Top Tips for Long-Term Rust Protection

• Apply underseal annually, especially if you drive through grit or coastal areas

• Use cavity wax in hidden areas like sills, doors, and chassis rails

• Repair any stone chips or paint scratches as soon as they appear

• Wash the undercarriage after winter — moisture and salt exposure accelerate oxidation

• Consider full automotive rust protection if your car is over 5 years old

For enthusiasts and daily drivers alike, we offer tailored rust protection and refinishing services. Contact us directly for quotes or to discuss custom protection plans for your vehicle.

Does Insurance Cover Rust Repair?

One of the most common misconceptions about rust is that it might be covered by insurance. Unfortunately, in almost all cases, car rust repair is not included in standard insurance policies.

Why Insurance Usually Doesn’t Help:

• Rust is classed as wear and tear, not sudden damage

• Policies exclude issues caused by long-term neglect or environmental exposure

• Even cosmetic rust often falls outside coverage unless it’s part of a larger accident claim

That said, if rust damage has been exacerbated by a collision or poorly executed past repair, there may be room for negotiation with your insurer — especially if you use an approved repairer like Sprayshack Ltd.

"While not covered in most cases, insurance can occasionally support rust repair if the corrosion stems from collision damage that your policy does cover."

If you’re unsure where your case stands, our team is happy to help assess the situation and communicate with your provider.

The Rise of Mobile Rust Repair: Convenient but Cautious

We live in a world of convenience. From food to fitness to car care — everything can come to you. So it’s no surprise that mobile rust repair services have started to gain traction.

Pros:

• Convenient for surface rust touch-ups

• Cheaper due to reduced overheads

• Great for selling prep or lease returns

Cons:

• Limited in tools, especially for penetrating rust or structural components

• No access to full spray booths, so paintwork/respray jobs may be lower quality

• Often cannot perform extensive welding or panel replacement

Mobile options are great for quick fixes, but if you're looking for quality, longevity, and MOT-compliance, it’s best to visit a dedicated facility — like ours, equipped for full automotive restoration and corrosion correction.

Selling a Car with Rust: How It Affects Resale Value

Rust is more than just an aesthetic issue. Even minor rust blisters or rust bubbling under paint can knock hundreds off your car’s market value — especially in the private sale market.

How Rust Impacts Vehicle Value:

• Reduces buyer confidence in car condition

• Hints at hidden rust damage elsewhere

• Suggests poor maintenance habits

• May cause issues at pre-purchase inspections

If you’re planning to sell a rust-affected vehicle, consider a rust repair service as an investment. Spending £400 on a quality repair could increase your resale price by £1,000 or more, particularly on enthusiast or classic vehicles.

Before you list your vehicle, a quick visit to a professional inspection centre can help you understand what’s fixable — and what’s not.

Final Thoughts: Should You Fix Rust or Move On?

Ultimately, the decision depends on three things:

1. The severity of the rust — Is it cosmetic or structural?

2. The value of the vehicle — Is it worth the investment?

3. Your plans for the car — Keeping it long-term or prepping for sale?

If your rust is moderate and repairable, it’s always best to address it early. Rust never improves with time, and ignoring it only compounds the damage and the expense.

Let’s Wrap This Up:

• Rust repair cost ranges from £150 to £3,000+, depending on location and severity

• Address surface rust early to avoid costly panel replacement later

• DIY fixes can work, but professional repairs offer durability, resale value, and peace of mind

• Don’t wait until an MOT rust failure to act

• Invest in underseal, cavity wax, and rustproofing to stop future issues before they start

Need Expert Help?

If you're unsure whether your car needs rust repair or just a touch-up, we’re here to help. With a reputation for high-quality refinishing and honest pricing, Sprayshack Ltd is the go-to choice for rust repair in the UK.

From initial inspections to rust removal, welding, and paint matching, we’ve helped countless drivers preserve their vehicles and protect their investments.

Got questions or ready to book? Get in touch with us today and let’s talk rust — before it gets worse.

Frequently Asked Questions: Car Rust Repair Costs

1. Can I get a quote for rust repair without bringing the car in?

Yes, many garages — including ours — offer remote estimates if you provide clear photos of the affected area, car make/model, and your location. However, a final quote may change after a full in-person rust inspection, especially if there's hidden rust beneath the surface.

2. Is it cheaper to fix rust on older cars or newer cars?

Generally, older cars cost more to repair because rust may have penetrated deeper and parts may be harder to source. However, newer cars with aluminium panels or advanced coatings may require specialised materials or tools, balancing out the cost.

3. Do I need to fix rust before selling my car?

It’s not required, but repairing rust before sale can significantly increase your resale value, especially for private buyers. Cars with visible rust often deter potential buyers or are used as bargaining chips to reduce your asking price.

4. Is rust repair different for electric or hybrid vehicles?

Yes, a little. EVs and hybrids often have battery packs mounted to the chassis, meaning repairs near the underbody or sills require extra care, insulation protocols, or sometimes specialist equipment, slightly increasing the labour cost.

5. How long does a rust repair take?

Minor rust repairs may take 1 to 3 hours, while severe cases involving cutting, welding, and painting can take 2 to 5 days. This depends on rust location, parts availability, and drying time for primers and resprays.

6. Can rust return after being professionally repaired?

Yes, if not treated properly. However, a quality repair that includes metal replacement, rustproofing, and sealing can prevent recurrence for years. Adding annual underseal touch-ups helps extend protection — especially in UK climates.

7. Is it cheaper to repair rust in summer or winter?

Prices don’t usually fluctuate seasonally, but workshops are often busier in winter due to increased corrosion from salted roads. Booking in summer may offer faster turnaround and better availability.

8. Can I repair rust damage in stages to spread the cost?

Yes. If you’re on a budget, some repairs can be done in phases — addressing structural or safety-critical rust first, followed by cosmetic fixes later. We offer flexible rust treatment options to help you prioritise without compromising safety.

9. How do I know if rust has affected the structure of my car?

Structural rust isn’t always visible. Signs include:

• Unusual creaking or flexing

• Visible rust near suspension mounts or seatbelt anchor points

• Failed MOTs citing corrosionWe recommend booking a vehicle inspection for rust if you notice these issues.

10. Do rust repairs come with a warranty?

Yes, many garages offer warranties for rust repairs — ranging from 6 months to several years, depending on the repair method and materials used. Always ask for this upfront and keep documentation in case rust returns.