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Failed your MOT on rust? Star Welding Mansfield specialises in MOT welding and rust repair for cars, vans and light commercials. We focus on the exact points listed on your MOT sheet, carrying out proper welding so your vehicle can be retested safely and legally. All MOT welding is carried out by B6 & 6G coded MIG and TIG welders, following MOT‑standard repair methods.
Corrosion around sills, chassis rails, floor pans and suspension mounts is one of the most common reasons vehicles fail their MOT. A quick patch or filler won’t fix the problem – the rust has to be cut out and replaced with solid metal.
When you bring your MOT failure sheet to Star Welding Mansfield, we:
Sills and floor pans are frequent MOT fail points, especially on older cars and vans. We remove rotten metal from inner and outer sills or floors, then weld in new sections shaped to your vehicle. The result is a solid, continuous repair that satisfies MOT standards rather than a thin patch over rust.
If your MOT has flagged rust near suspension mounts, seatbelt mounts or chassis rails, we treat these as priority repairs. We rebuild the strength with new steel, ensuring mounts and brackets are properly supported and welded so the structure is safe under load and braking.
MOT welding costs depend on where the rust is, how far it has spread, and how much solid metal remains once corrosion is cut back. What looks like a small patch from the outside can often reveal more damage underneath.
As a guide only:
Small localised weld repairs can start from a few hundred pounds
Sill or floor pan sections usually cost more due to access and preparation
Chassis or structural repairs are priced based on safety-critical work and complexity
We always inspect the vehicle before quoting. That means no guesswork and no surprises once work begins. If welding is not the right option, we’ll tell you.
If your vehicle has failed its MOT due to rust or welding issues, you cannot drive it normally on the road. The only legal journeys allowed are:
Driving to a pre-booked repair appointment
Driving to a pre-booked MOT retest
Driving a failed vehicle outside of this can invalidate insurance and lead to penalties. If you’re unsure whether your vehicle is safe to move, contact us first. We’ll advise whether it should be driven or recovered.
This is one of the most common questions we’re asked, especially when corrosion affects structural areas.
MOT testers focus on strength, safety, and repair quality. Cosmetic fixes do not pass. For welding repairs to be accepted, they must:
Be fully welded to solid metal, not rust
Restore the original strength of the area
Cover the full extent of corrosion
Be secure around mounting points and load-bearing sections
We weld to MOT standards, not minimum appearance. Repairs are cut back properly, welded continuously, and protected after welding. If needed, we can provide photos of the work for your MOT tester.
From MOT Fail to Retest: What Happens Next
The process is straightforward:
You bring the vehicle in or send clear photos of the MOT fail areas
We inspect the corrosion and confirm what needs welding
You receive a clear explanation and price before work starts
Welding repairs are completed to MOT standard
You return for retest with confidence
Our aim is to get your vehicle safe, compliant, and back on the road without unnecessary work or delays.
