Dropped the tank today, and found the source of my gas fumes/overflow when filling. Smaller vent line off the tank was ruptured. I actually realized I could have seen that if I looked through the louver slots in the tail panel. Didn't want to drive to Carlisle without being able to fill the tank.
Manual for reference
filler neck base & clamp in great shape.
Removed the remnants of the right side bumper shock, and plugged all the holes. Added butyl to ensure a seal
Had to pull out the bottom of the tank a little. I realized there was no way to lever in there from the fuel sender port as there is a baffle in the way. So I just put a threaded bolt in the drain plug and levered the sucker out evenly working around the circumference of the bolt/plug hole
Degrease / clean and paint tank.
Made an elbow to replace the original large loop, the small line I just ran a longer piece, so it could loop gently
Visible through louvers beneath bumper.
For the inside, I cut the original hose - most of the inside was perfectly good there was no cracks in the the material, so I just ran a splice section from the tank, and used a large quick connect to join the two. new grommets for the lines from ZcarDepot.
I did find out that I put the sender in upside down, as when I started it the gauge pegged full. Drained about 4 gallons, prior to doing the work.
I realized the notch in the sender plate was supposed to be on the right not on the left - upside down in this pic