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What type of Valve Covers do You have? Why do You even have a catch Can? Sounds like some sort of Engine Build were trouble was exspected and now you have it. I'm in the same boat however, I have a Turbo Charged engine and my Engine builder told me to be very careful with the baffels in the Valve covers and I paid no attention to him and have been battling Oil passing threw the PVC ever since. I think a catch can is in my future as well. The factory baffels seem to work best and a lot of the aftermarket ones don't work as well and or as in my case there are none. On a Street engine they are needed.
Long story short. I had several tuning issues with a stock style pcv letting the engine pull too much air through it. The vacuum level of the engine was not high enough to get it to close at the proper time. I since then switched to a tunable pcv. The manufacturer advised to use an oil catch can and baffling.
I tried several setups, but none have worked sufficiently so far.
Due to the catch can I can see the amount of oil being deposited there.
The engine is equiped with shaft rockers and high pressure springs (roller setup) + spring oilers and thus requires the use of tall, non stock covers. I use edelbrock elite's.
I know the stock pcv baffling is best, but they simply don't fit the rocker system or the springs as the baffle reaches down to the head.
Someone suggested cutting off the bottom of a soda can, drilling holes around the circomference and welding it in. Haven't tried that though.
It's not so much the oil usage that I consider the biggest problem, but oil ending up in the combustion chamber. I'm running 10.6/1 CR and oil leads to premature detonation and pre-ignition.
Stainless dish washing pot scrubbie from the grocery store works very well to keep the oil in the covers.
If you don't have the baffles, then maybe you can weld something on top of the valve cover. With the engine off, any accumulated oil runs back into the engine.