High-Performance Exhaust Solutions Built to Last
Whether you need a simple exhaust welding repair to pass your MOT or complete custom exhaust fabrication for a classic restoration, Alpha Welding & Fabrication delivers precision engineering right here in West Sussex. We combine years of specialist automotive welding experience with advanced TIG and MIG processes to create durable, high-performance exhaust systems that stand the test of time.
From stainless steel pipe welding to intricate manifold repairs, our Rudgwick-based workshop is equipped to handle everything from daily drivers to high-performance track cars.
Call us on 01403 458874 or get a free quote online.
Why Choose Alpha Welding for Your Exhaust Needs?
Your vehicle’s exhaust system is critical for performance, efficiency, and sound. A cracked manifold or a rusted flange can ruin your driving experience and lead to MOT failure. At Alpha Welding & Fabrication, we do not just patch holes; we engineer solutions.
Founded by Charley Moroney in 2012, our business started as a one-man operation in a garage and has grown into a premier fabrication service in West Sussex. We now operate fully equipped workshops in Rudgwick alongside a fleet of mobile teams. Our reputation is built on dedication, skill, and the ability to bring even the most complex “weird and wonderful” creations to life.
Our Core Unique Selling Points
- Decade of Expertise: Established in 2012, we have grown from a garage start-up to a leading local authority on automotive fabrication.
- Accredited Professionals: Our team holds CSWIP and TWI accreditations and is CSCS Approved. We are also Network Rail Sentinel compliant, proving our commitment to safety and quality standards.
- Specialist Materials: We are experts in stainless exhaust welding, aluminium, and mild steel, ensuring the right material is used for every application.
- Comprehensive Service: From on-site mobile welding repairs to full workshop-based custom fabrication.
Expertise Backed by Motorsport Experience
At Alpha Welding & Fabrication, our expertise extends beyond the workshop floor. Charley Moroney, our founder and director, is not only hands-on with the day-to-day business but is also a competitive BTRDA RallyCross driver. Through Moroney Motorsport, Charley applies the same technical precision and problem-solving skills learned in the heat of competition to every customer project.
Motorsport is not just a passion for us; it is a natural extension of our engineering capabilities. This real-world experience ensures that whether we are performing a simple exhaust welding repair or undertaking a full custom exhaust fabrication, your vehicle benefits from the same discipline and attention to detail required for high-performance race cars. This connection gives us a unique insight into vehicle dynamics, durability, and performance, guaranteeing you receive a service built on genuine automotive expertise.
Our Specialist Exhaust Welding Services
We provide a full range of exhaust services tailored to the specific needs of West Sussex motorists and car enthusiasts.
Exhaust Welding Repair
Rust and vibration often cause cracks in exhaust pipes and silencers. Replacing the entire system can be incredibly expensive. Our exhaust welding repair service offers a cost-effective alternative. We cut out the rot, prepare the metal, and weld in new sections to restore the structural integrity of your system. This is often the smartest route for MOT repairs where a replacement part is either unavailable or prohibitively expensive.
Custom Exhaust Fabrication
For those who demand more from their vehicle, off-the-shelf parts simply will not do. We specialise in custom exhaust fabrication, building bespoke systems from scratch. Whether you need better flow for performance, a specific sound profile, or a system rerouted for ground clearance, we design and build it to your exact specifications.
Stainless Exhaust Welding
Stainless steel is the material of choice for longevity and aesthetics. However, it requires specialist knowledge to weld correctly without compromising corrosion resistance. Our team uses precision TIG welding techniques for stainless exhaust welding, ensuring clean, strong, and visually appealing welds that resist the elements far better than standard mild steel repairs.
Exhaust Flange Welding
Leaking flanges are a common MOT failure point. Rather than scrapping a good exhaust due to a failed connection, we offer exhaust flange welding. We can replace warped or rotted flanges with new, heavy-duty versions, ensuring a gas-tight seal that restores backpressure and eliminates dangerous fumes.
Stainless Steel Pipe Welding & Modification
Modifying an existing system? We offer precise stainless steel pipe welding to alter routes, add flexible sections, or install new catalytic converters and silencers. Our fabrication team ensures that every join is perfectly aligned for optimal gas flow and durability.
The Alpha Welding Process
We believe in transparency and engineering discipline. When you bring your vehicle to us for custom exhaust welding or repair, we follow a strict process to ensure quality.
- Assessment: We inspect the damage or discuss your custom requirements. We check for corrosion, stress cracks, and mounting issues.
- Preparation: Good welding requires clean metal. We remove rust, grease, and old exhaust paste to ensure a sound base for the weld.
- Fabrication: For custom work, we measure, cut, and tack-weld the new stainless exhaust fabrication sections in place to check fitment.
- Welding: Using the appropriate MIG or TIG process, we complete the welds. TIG is often used for stainless steel pipe welding to ensure a neat, high-strength finish.
- Quality Check: We inspect the work for penetration and seal quality before handing the vehicle back to you.
Case Study: Classic Fiat 500 Restoration
We recently undertook a comprehensive restoration project on a classic Fiat 500, which required extensive metalwork and fabrication. This project highlights our ability to handle delicate, vintage machinery with the care it deserves. Whether it is a full make-over or a specific exhaust pipe welding job, we apply the same level of craftsmanship. Read more about the Fiat 500 project here.
Expert TIG & MIG Capabilities
Different exhaust jobs require different approaches.
- TIG Welding: Essential for stainless exhaust fabrication and thin-walled tubing. It allows for precise heat control, resulting in beautiful “stacked dime” welds that are as strong as they are good-looking. This is our go-to for custom headers and visible tailpipes.
- MIG Welding: Ideal for mild steel exhaust welding repair and attaching heavy-duty hangers or flanges. It provides deep penetration and robust strength, perfect for under-car structural repairs.
Serving West Sussex and Beyond
Based in Rudgwick, we are perfectly positioned to serve the entire West Sussex area. We routinely welcome customers from Horsham, Crawley, Billingshurst, and surrounding towns who are looking for reliable custom exhaust welding.
While we offer mobile welding for structural repairs, we recommend bringing your vehicle to our fully equipped workshop for exhaust work. This allows us to use vehicle lifts for better access and ensures the highest quality results for intricate stainless steel pipe welding tasks.
Frequently Asked Questions
Yes, we frequently perform exhaust welding repairs to pass MOTs. We cut out the corroded area and weld in fresh metal patches or new sections of pipe to ensure the system is gas-tight and secure.
Absolutely. Our custom exhaust fabrication service covers everything from manifolds back. We can build systems in stainless steel for increased durability and performance.
Stainless steel is much more resistant to rust and corrosion than mild steel. While stainless exhaust welding requires more skill and specialist consumables, the result is a system that can last the lifetime of the vehicle.
Yes, exhaust flange welding is a common service we offer. If the flange has rotted away but the rest of the pipe is healthy, we can weld on a new flange to save you the cost of a full replacement.
It is always best to book in advance. While we try to accommodate urgent repairs, our workshop schedule fills up quickly. Contact us to discuss your needs.
Contact Us Today
Ready to fix that exhaust blow or start your custom build?
Call us: Office: 01403 458874 or Mobile: 07917 390669
Message us: WhatsApp: 447917390669 or Email: info@alphawelding.co.uk
Or, fill out our online form to get a free quote and we will get back to you promptly.
About West Sussex
West Sussex is a historic county in the south of England, known for its diverse landscape that ranges from the rolling chalk hills of the South Downs National Park to the coastal plains. It has a rich automotive history, home to the world-famous Goodwood Festival of Speed and Goodwood Revival near Chichester, which attract motoring enthusiasts from across the globe. With major towns like Crawley, Horsham, and Worthing, the county is a hub of activity while retaining its rural charm with stately homes like Petworth House and Arundel Castle. This strong motoring heritage makes West Sussex the perfect base for specialist automotive engineering and fabrication services.
