A method for repairing a rotor wheel including an airfoil using a blade repair assembly is disclosed. The blade repair assembly includes a first block and a second block, each including a contact surface with a shape of at least a portion of the airfoil and a cavity surface adjacent the contact surface. The method includes pre-machining an airfoil edge to a uniform height. The method also includes clamping the first block and the second block to the airfoil forming a cavity with the cavity surfaces and the airfoil edge. The method also includes filling the cavity with a metal including metallurgically bonding the metal to the airfoil.