My 528 hemi has developed a small valve cover oil leak. I thought i could get lucky and snug down the valve cover bolts. The valve cover bolts were super loose, but snugging them down caused a ticking noise which I think is the rocker hitting the baffle. I loosened the bolts back up and the tick is gone, but the oil leak returns. Valve covers are MP chrome ones.

Can I just dent the baffle to create a little more clearance without hurting the chrome valve cover external appearance?

Any suggestions on what brand of valve cover gasket for a replacement?

Shouldn't be a problem. We had one recently that the baffle came loose and was hanging by one spot weld. NICE
They do make thicker gaskets and I do have a pair. that I don't need as I sold the car. They are Fel pros I believe, cork and I'm guessing either 3/16 or 1/4 " thick
PM me if your interested

Mine did the same thing. I massaged the baffles inside the cover and used superformance thicker gaskets, leak and tapping resolved.

I had the exact situation on my Hemi. Tighten them down to stop leaks, and then get tapping. On mine, it was the exhaust rockers hitting the valve cover itself. Double gaskets didn't fix it. Ended up dimpling the valve covers at the points of contact and refinishing them and adding the extra gaskets. The hard Superformance gaskets helped because they don't crush as much as the cork or rubber ones do. But I had to trim them to fit.

I also used valve cover bolt brackets. Had to trim them to fit but when I painted them to match the valve cover finish, you don't notice them. On my steel covers, they really helped to reinforce that area and spread the load so that I could pull the valve covers down tighter.