Warped Upper Valve Covers - Replace?

[jcarpio]

Greetings everyone -

I've got a stock '72T that leaks oil while sitting, about 10 big drops a week. When running, after a long (460 mile round trip) drive, the oil level on the dipstick went from midway between the lines to the very bottom line. I've noticed recently that the upper valve covers may be the source. They are so warped you can actually see gaps that are about 1.5 mm wide. It's clear that oil is coming out of those gaps.

My questions are: Is this level of oil consumption normal? Am I asking for trouble (catastrophic engine damage) by not replacing the valve covers ASAP? Will I be OK by dealing with the leak by religiously checking the oil level and filling as needed? I would fix the covers but I'd like to spend my money first on installing an oil cooler to get ready for summer. I suppose the oil cooler would work better if there weren't leaks in the system...

Any advice is greatly appreciated.

Thanks,

Jorge

[Bobboloo]

You can resurface the valve covers by taking them to a machine shop or by getting a piece of glass (flat surface) and some sandpaper (wet) and doing it yourself.

If you do it yourself then get some autobody sandpaper that you can use wet. The water allows you to rinse the sandpaper as you work so it won't clog. 300-400 grit should do.

Use new gaskets and nylock nuts when you replace the covers.

[Eric911S]

Hello: Belt sander is the way to go! Take the covers to a machine shop that does Aluminum cylinder heads for cars. Most shops have a wide belt sander to refinish the heads mating surface. Good luck. Thanks Eric

[lisa_spyder]

We send batches off to our machine shop to mill them flat again. Haven't had a problem since. Then we sell them on a changeover basis to keep the cost down and replenish our stocks. We used to finish them by hand in the shop with the sandpaper idea, but it was very time consuming and not always successful (OK if you're doing it for yourself and don't have to justify a charge ).

Getting them milled is great, but not economical for one set as the set up time for the mill can be rather costly. Try Eric's sandbelt idea as for one set this would be cheaper for you.

And as bobboloo says - always use new fasteners (including washers) and gaskets...

Cheers,

Lisa

[jcarpio]

Thanks for the help, I've been meaning to get a belt sander, now I have a good excuse.