i have a small leak in the upper portion of the filler pipe and have some gas line hose of the right diameter to make a bridge. In hack sawing the filler tube to accommodate the hose, is there any chance of a spark igniting fumes and detonating the gas tank or do I need to remove the entire assembly before making the cut?

 

I personally wouldn't take that risk while its still attached to the tank. In this instance, I would just replace the entire filler neck if I have to take it off to weld and the retest after to make sure it doesn't leak.

 

^ yeah def not worth the consequences.

 

you can't really get a saw on it while installed anyway, so i pulled it out, cut a length out from about 6" from the filler opening to the first elbo and then put in a piece of gas hose i got at pullyard for $1. Poured a gallon in from a portatank and back in business. my 97 filler neck is only the vent and gas line as opposed to other editions where all the evap lines are part of the assembly, i prefer my setup for repairs for sure.

 

I just did that repair. The assembly comes out easily, then you can cut and splice the hose in. I did mine this past spring.