Leaky valve cover follow up.

33IMP said
I would clean the gasket and all sealer off the cover, and fit it to the head, without a gasket, to see if it sits flat, or has a rock or a space that you can get a substantial feeler gauge through.
A bad cover flange on the head and the angled cover bolts will make a cast cover hard to seal. The fabbed covers can be even worse.
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I checked the head and the valve cover. They are not laser flat, but it is so minimal the square only moved 64th inch (Nothing really). I removed the gasket and it is split in two almost the entire length of the lower section. Obviously it is on WAY to tight.