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I do believe that the catch can has to be big enough and baffled internally to allow it to function as an oil/air separator. Also it can't hurt to have a look at what is going on under the cam covers either. There is a lot of heavily oil-laden air being shifted through those lines, so your system has to be able to knock the heavy mist down.

Here's a build that has been experiencing the same sorts of issues. Check from about post #101 http://www.skylinesaustralia.com/forums/topic/352798-zoids-gts-build/page__st__100

And I also think that if you are using a full synthetic engine oil, go to a mineral base.

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