I have been using Rotella 15W-40 as well for over the past 6 yrs now. I did a 3000 miles round trip from Los Angeles to Montana and i burned about a quart in doing so.
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A catch can is on my list, possibly the one from Epic Cruisers when they're back in stock. Where'd you get yours or did you build it yourself?I think the oil consumption on any of our LandCruisers is a combination of Valve Stem Seals, PCV and blowby past the rings due to high RPM operation or under heavy load, or both.
Personally, I'm a bit surprised at the oil catch can which needs to be dumped every fill up, as it always contains a few fluid ounces of engine oil which otherwise would have been ingested by the engine via the intake, or coated the inside of the intake manifold requiring cleaning at some point.
Yup, mine is the $15 air compressor filter from Home Depot. Only holds about an ounce but does the job!Catch Cans are stupid simple, but people like to make $$$ and customers like shiny new things. Just get the inline plastic filter with stainless screen element from Summit or wherever and cut your existing vacuum hose going from the top of the valve cover to the intake, placing the filter where convenient.
The stainless screen is relatively cooler than the oil vapor drawn out of the valve cover area, so the oil condenses. The air travels it's own happy way, just like its supposed to.
At least then you're recovering some of the oil that would otherwise be burned or formed into hard deposits...