Sounds like perhaps a pair of problems to me.
The pan being sheet metal is really prone to getting tweaked, either by over/under torquing it or just bumping it while it is off. On their next gas motor Isuzu switched to an aluminium pan, likely to avoid these problems. (And create new ones

)
I'd locate another pan somewhere, clean it up, check and recheck it for straight, and tap out even the smallest dings before putting it on. Also a good time to paint the outside of it and make things all pretty when it goes back together. A good gasket goes a long way too, as does some sealant. As you said, you don't want to do this again, so when in doubt replace everything involved.
The other thing is it does sound like there is too much pressure in the crankcase. I bet the PCV hose/valve deal is not working right. The LUV 1.8L has a thing like a PCV valve, only instead of being right on the valve cover, the business end of it is buried under the carb on the intake manifold. It is the smaller hose that hooks into the front right of the valve cover (not the big one towards the rear, that is supposed to go into the air cleaner). Take that hose loose and try squirting something like carb cleaner or SeaFoam DeepCreep down it. That might clear it out and help relieve the pressure from inside the motor.