So as I was doing this mod, I checked some things out.
I noticed that the line from the catch can to the manifold, the hose that is under vacuum, was pretty much bone dry. Now, I checked and there is no blockage, the system is drawing a pretty strong vacuum when the motor is idling. I can remove the dip stick from the top of the catch can, and there is strong suction and a whooshing noise...
So why no real oil in the return line? Because the catch can seems to be doing it's job. After 1,500 miles I have collected several ounces of motor oil and a little bit of water. Now, I know that you said that it only works when it is cold, via condensation. One thing that I changed on my catch can, was inside, there is a smaller "canister" that screws into the lid. It is connected to the line coming from the crankcase vent, and the hot air must pass through this cylinder and exit out the bottom via some holes... That inner cylinder unscrews from the lid, and I filled it with moderately packed, very fine steel wool, and screwed it back in. The hot oily air being sucked in via the vacuum line, is forced to pass through that steel wool "filter", if you will, with causes the mist to form droplets and separate out and drip into the bottom... Those droplets are too large to get sucked up into the very top of the lid where the return line is...
It's working, it's collecting more oil than I expected it to so nothing is clogged or blocked, but clearly it's trapping 99% of the oil from going back into the motor. I looked down that return line and couldn't see any oil in it, and it felt almost bone dry... hardly anything...
I then checked the valve cap lines and there was next to no oil in them, minimal at best.
So at this point I left my filtered catch can as it was, as it appears to be doing it's job of collecting oil and passing almost nothing back to the manifold. I then did the Seafoam intake cleaner treatment... only got about 3/4 of the bottle in there because the staw wouldn't attach to the cap and I had to sit there trying to hold it in place... But after that and letting it sit 15 minutes to heat soak, I went out and got on it and left a big cloud of white smoke in my neighbor's yard... sorry bout dat... lol
I will redo a new can of the Seafoam this weekend and make sure to do the entire can this time, but everything seems fine. I think that for whatever reason, my setup is in fact catching almost all of the oil and very little is passing to the motor and intake valves, and so another good cleaning and it should be fine and I won't worry much about it going forward...