Leak Proof Valve Covers
Yes, it's overkill.
Okay, leaking valve covers. How do you fix them? Depends on who you ask. Seriously. As for the way I do them, I don't change my valve cover gaskets with each valve adjustment. I am able to re-use them time and time again. First thing I start with is welding a thin tab to the bottom edge of the inside. If you look closely at the picture to the right, you can see it. If you do this to your covers, make sure you put it somewhere that it will not get in the way of the rockers. I welded mine in, because I went to the track while trying out some solid rubber valve cover gaskets. Figured I'd see how they work. Well, put smooth rubber against smooth metal, and throw in some slick oil to boot, and you've got a valve cover gasket sucked in and throwing oil all the way down the track. I shut my local track down for a good 20 minutes. Not cool.
So, I welded in some tabs, and that cured the sucked in valve cover gasket problem. But, it was still a bitch to get the valve cover on my car without the valve cover gasket coming out of place. being that I have an 82mm stroker, and an early body, it's a tight fit between the valve cover and the body. I would always catch the gasket on a rocker, and it would come out of place. I knew there was a reason I always glued my gaskets in place....
Now, if you can find them, there is somewhere that makes a 'thicker' cork gasket for the valve covers. These are nice because they help you get a tighter fit on the valve cover. If you look closely at the picture on the left, you can see how I fixed the problem. I used my torch to put a small weld on the two places in the middle groove where the bail clips in. This adds a bit more pressure to the valve cover and helps prevent leaks. You do have to make sure that you do get the welds lower than the high point of the cover, so the bail wont pop off.
I like to prepare all my surfaces that I am going to put sealant on with brake cleaner. In this application, I sprayed some on my rag, and wiped it down. This is done with a valve cover that has no old sealant on it already. If your cover has sealant on it, get it all off. I found that a bucket of water and a an SOS pad works great. Now that your cover is all ready, next comes the part that ensures 'no leaks'.
Find an old VW head. If you dont have one around your garage, check with a local VW shop to see if they have any junk ones. You could probably pick one up for cheap if you get a really junked up one. For me, an old GEX head fit the bill. Clean off the gasket seating area and make sure you have a good bail on it.
Next, put some sealer on the clean valve cover, and apply your gasket. I've tried cork, and i've tried rubber, and by far, the cork works best. Put the gasket in place, and press it down a little bit into the sealer. The sealer I have used here is Permatex's 'the Right Stuff'. It seems to work good.
Now, you can put the valve cover straight onto the head without having to worry bout fitting it around the rocker arms, and the body, with the risk of snagging the gasket on something and making it botch the whole thing.