What's the lift on the cam?
TQ you don't have to replace the covers, you can take a die grinder and cut some of the webbing from the cover in the areas where Glider's pictures show. Might be a good idea to do even if they are not hitting. I even noticed in one add for the Andrews cams that it said to check for interferance between the cover and spring. Also mentioned about spring binding but I don't think that our cams lift is that radical.
When I changed the cover gaskets in my 1200 Buell I used James gaskets. They were a lot thicker that the Harley gasket. Glider do you think the James might be a cure.
TQ, check out this post about type of tappets used posts #14 & #18:
http://www.hdtimeline.com/oil/13371-whick_oil_is_ok_for_my_bike.html
I hate to sing like the choir, but like Glider said, while the covers are off, inspect the cover webbing areas for a wear pattern associated with something hitting them... can't hurt. Most of those casting will have "hogout" milling machine marks that are smooth and distinct...something clattering would have indentations that are random or look like "chatter" or similar nick marks.