No dice. Looks like it leaks substantially less, but still enough to smoke. Figure it's just gonna bend wherever the new weak link is between weld and old tin, and not give me enough clamping force.
Not sure what consumption is, but you can smell the smoke in the cab when you're not moving, and 90% of this truck's purpose is to tow my boat in the summer, which is basically guaranteed bumper-to-bumper traffic.
I guess I can try to cut a spreader ring that hooks all the way around that corner to the next 2 bolt holes, or rebuild the entire flange like rhekman did. I have zero experience on the plasma cutter, though.
Do 2.8/2.9 covers fit the 4.0? Modifications needed? Apparently UK ebay is lousy with them, they just don't come up right away because they call valve covers "rocker covers". Lot of 'em look rusted to shit as well, though.