I straighten the covers before sanding them smooth. The more metal you remove from the cover the worse the problem will be.
I use a piece of steel about 1/4 inch thick by 1/2 inch wide to make a reinforcement bar to keep the gasket from being blown again. Use the bar to span the cover over the area where the gasket blows out. You will have to notch it a little in the middle to clear a rib in the cover. Put a slight bow in the bar so that the middle contacts the cover before it is tighten down completely. You will need to replace the bolts that go through the bar with longer ones so that the thread engagement in the pump housing remains the same.
I have been using this method of repair for about 30 years and have never had a repeat failure of the gasket in any of the pumps repaired. I think that this method is easier than trying to make a new cover.
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