Copied from my post in the SAMBA (I figure it may help someone here)
Post Posted: Sun Jun 15, 2014 9:18 pm . . I've been at it nearly all weekend (on and off between other projects).
I really got intimate with the cover after finding none available (if you know of new ones please post a link).
One issue with the rubber gasket - we are really sealing two cracks; one between the cover and the gasket, and another between the gasket and head.
Any-who, I found the left lower corner to be bent slightly upwards. I started by checking the width of the flanges and the front was narrower by 0.01" not much I know, but I am seeking perfection at this point.
I did some tweaking on my steel bench with a dead blow and some spacers and feel it's very flat across all four corners (now it's the same width as well).
EDIT I've decided to let it sit another day. If it's not sealed now, I may go to the guy selling these motors used and see if he has a cover. I sent him an email
With a new gasket placed on the head (I have a spare), I buffed the flange of the cover with a wire wheel till it was a bit grainy and spotless. Next step was to squirt a narrow bead of The Right Stuff on the flange and lay it on the gasket mounted on the head. I laid a few chunks of steel on top - maybe three lbs, and let it sit for six hours.
The gasket is now nearly part of the cover and sits relative to the head. There will be no leaking from that joint.
One down, one left to go.
On the joint between the cover (with gasket firmly sealed to it), I used Hylomar (both surfaces). Let dry for ten minutes and assembled.
Posted: Today 4:23 pm. . .I did my "take it to work" test run toady to check for valve cover leaking.
It's about 26 miles each way, southern CA freeway (65 is slow), three long grades averaging about 2%.
When I arrived and peered under the back, there was no oil dripping off anything - good sign.
On closer inspection, there is a tiny amount running down the head in the typical place - just a whole lot less. Smile
I'm tempted to quit now but it will be a mess after a few K miles so I'm going after it one more time. My guess is the dabs of HYLOMAR in the corners of the cam cap weren't enough. Once I get it off, it will be clearer.
BTW, I called the local VW dealer and a new AAZ cover is available - about four days (from Texas). The cover is $242.33 + tax.
I think I'll give this one more try possibly tomorrow afternoon.
If my next attempt fails, it's new valve cover time - I despise oil leaks.
