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What can happen to a car when the fuel filler neck is rusted and has a hole in it, other than gas spilling out?
My fuel filler neck is rusted with holes in it. I've tried to use liquid metal to cover the hole but the rust damage is just too great. I feel like its what is keeping my car from starting because I purchased a new car starter and installed it. Sometimes it turns on and sometimes I end up needing a ride to work. When it DOES turn on it smells strongly of gas and I feel like my gas mileage is shot.
Of course there is a risk of fire but considering how common fuel leaks around the filler neck are I don't think it is extreme. The flammable range of gasoline in air is fairly narrow (1.4% to 7.6%), which explains why most accidental gasoline ignitions are situations where the vapors can creep along floors until the vapor/air interface finds an ignition source.
It certainly isn't doing your gas mileage any good. You don't mention make, model, or year, but if it is recent at all it almost certainly uses electronic fuel injection. EFI fuel pressure regulators work by bypassing gasoline as necessary to produce the required pressure so there is a constant stream of gasoline being poured back into the tank. That can only increase the amount lost through the holes.
And of course there is the smell.
The filler neck is a separate piece in most cars - maybe you can get a replacement? It would be good to have the seal(s) that go with it, too. This is the type of repair that really produces a feeling of relief when it is done.
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