Drill a hole into Fuel Filler Neck?

Johnny,

This fuel sending unit has 1 port that went to the Char Cannister. It has a pinhole opening which I'm assuming is like on the other end of the factory vent tube which is a check or pressure release inline valve. I'll look at the FSM to see. I cut off the 1/4" vent tube back an inch the one engine bay side so it will flow. I would have to drop the tank to either 1. trim the port on the sending unit to clear the restriction. 2. Get a new sending unit that is plumbed properly for a vent w/o restriction. From there add a short hose to connect the 1/4 line to the new sending unit. #2 being the best option. I could incur collateral issues from gaskets and rubber grommets etc. My current fuel system for a car that 45 years old works great (has been maintiained) as is and cracking the seal so to speak on it can be a slippery slope.

My 73 Dart only has 2 inches of open filler tube length between the fuel tank and the trunk floor, there is a rectangular rubber boot that screws onto my trunk floor that provides closure of the trunk area from the filler neck passing through. This is the top surface that the filler tube passes through, also a barb would have to slide through this and that won't work, there is just no room for hoses and a barb in general. The barb would have to be above that and in the trunk area on the opposite side. Soooooo, That why I was asking about everyone's half serious risk assessment of about drilling a hole. The McGyver in me says to wad up a wet cloth stuff it down the neck with a lanyard, blow in some fresh air, drill easily with some WD40 and some grease on/in the bit to hold debris. Pull out the rag with any debris! But I won't bet my life that this is a good process ! The more I think about it the filler neck barb probably should have a turndown to keep fuel from going into it when filling up! Not a perfect solution but easy and cheap. But wayyy up hill. Just trying to reduce effort and work but not take any unnecessary risks and get this right. Trying not to be pissed about my returnless system.

Thanks,

Marion