Bent valve cover

[etpm]

"Also, it looks like the crack appeared on the outside of the cover."

The crack was through before I started.

Then it should be soldered too. Grind or wire brush the crack area about 3/8" on either side of the crack. Then solder. The solder should tend to flatten out at the edges. If it does then you know it is wetting the aluminum well.
Eric

 

[quicksandfarmer]

An update: I had time yesterday to top up the oil and run the engine for about 15 minutes. I seemed to have stopped the leaking, at least for the time being. I realize my repair could fail at any time so I will keep my eyes open for a replacement cover.

 

[etpm]

An update: I had time yesterday to top up the oil and run the engine for about 15 minutes. I seemed to have stopped the leaking, at least for the time being. I realize my repair could fail at any time so I will keep my eyes open for a replacement cover.

Thanks for the update and good for you! I know everybody here truly appreciates the update. And the fact that you fixed it yourself not only adds to your confidence but also helps other folks who may be considering a similar repair. The repair doesn't need to be a valve cover, just an aluminum casting. And you just fixed yours! Even though I criticized your soldering job you showed me up by having a successful repair.
Cheers,
Eric