All cast valve covers leak. No matter what you do with Aluminum covers they will leak with headers
Sorry that you have had such crappy luck. I have found the cure:
The cast aluminum valve covers will seal as good or better than any other design, but you need to know a few tricks. First, use good gaskets, not flimsy rubber or cork. The black fibrous 1/4" thick gaskets from Fel Pro are a must. They are firm when new and seal better than anything else that I have tried. Not sure of the Part # but they are OEM replacements for a 1975 Imperial 440.
You need to lay a bead of RTV on the valve cover gasket rail, then set the gaskets on the covers. THEN I let the gaskets set up. After the gaskets are secure, I smear RTV between the VC and gaskets on the inside. This ensures that oil cannot get beyond the gaskets. At this point, the only place the oil can get out is from the space between the head and valve cover.
Not done yet, there is more.....
When setting the VC on the head, you will notice that the mounting holes in the VCs is bigger than the bolts, allowing the Valve Covers to move around. You want to put the bolts in loosely, then pull the VCs UP towards the intake while tightening. This ensures that the bottom gasket rail of the valve covers sits squarely on the head. I've found that the valve covers are a bit wider than the head and if the valve covers are allowed to sit too low, the bottom edge of the gasket is only about halfway on the head and the gasket distorts, allowing the leak. This is especially bad with rubber or cork because they are so flimsy.
Finally, I use special mounting bolts with a 5/16" head. They are easy to tighten with a socket and ratchet.
Merry Christmas.