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Our tank is larger than we can use in a trip (so far). So we usually only fill it 5 gallons at a time and no more than 2/3 or 3/4 full. So far our biggest issue is leaking on deck from those #$%&! jerry jugs with the so-called environmentally safe spouts.
On a power boat I used to have, I installed an inline whistle device where it would make sort of a low-whine/whistle while the tank was filling. Then when it was just about full, it would stop whistling (at which point you had maybe 1-2 seconds to respond and shut off before the fuel would come out the vent. Might not work well if you are hard of hearing or there are a lot of open-exhaust stink-boats running nearby. I think Attwood might have been the manufacturer. The other key is to make sure that the vent is looped to the highest point possible under the deck before exiting the thru-hull fitting. I haven't even looked at our vent installation on the T-37 as it was a new tank and racor filter in it when we got it. Professional work was done so had no reason to really pull paneling to inspect the vent... so far.
There used to be a device with suction cups that was stuck under the vent fitting to catch any fuel that popped out. West carried it, but I haven't noticed it in years if they still have it. Would be easy to make such a thing custom fitted for your boat. Might not get 100% of the spill, but 90% is an improvement.
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