GM's current lineup of LS-badged powerplants represent the pinnacle of OHV engine technology, combining class-leading output and fuel efficiency in a simple, lightweight, easy-to-manufacture package. The lone downside to this function- over-form approach to vehicular motivation may be found in the area of engine-bay aesthetics, where even the blower-topped, $111,000 Corvette ZR1 falls well short of competitive offerings from Ferrari, Aston, and Maserati.
But while cost and manufacturing considerations may prevent the C6 from ever flaunting the sinuous, red-crackle intake runners and delicate carbon latticework found under the hoods of its pricier rivals, that shouldn't keep a style-conscious Corvette owner from striving to present his or her engine compartment in the best possible light.
It's precisely that kind of thinking that inspired the creation of Billet Custom Products (BCP), the latest--and arguably the most ambitious--entrant in the growing field of high-end cosmetic enhancements for late-model Corvette engines. The firm's signature offering is a set of billet-aluminum LS valve covers, built to the exacting standards one would expect from an outfit with BCP's background.
"We recently celebrated our 30th year in business at Santourian Manufacturing Inc. [BCP's parent concern]," explains company principal Bruce Santourian. "We build for the aerospace, medical, and commercial industries [and] are heavy into supporting General Atomics Aeronautical's Predator UAV program.
"Our valve covers are a special, high-end item--maybe not made to fit everyone's budget, but made to be the best-looking and most-functional product we can build."
And indeed, at between $550 and $899 per pair (depending on features), these automotive objets d'art are the very definition of high end. But before you aspirate your Hubba Bubba, consider that the BCP covers feature one-piece billet construction, weigh an impressive 2.3 pounds less than the stockers, and--best of all--look like something straight out of a MoMA exhibit on the modern automobile. That they share a production lineage with the Hellfire-equipped drones that vaporized Anwar al-Awlaki and scores of other terrorist dastards is just an added bonus.
Optional features include full interior baffling (for better oil control in supercharged applications), a "tall" configuration (to accommodate aftermarket rocker arms), and a choice of finishes (finned or smooth, machined or show polished). The package comes virtually complete, with all required hardware, a container of Mother's aluminum polish, and the most impressive set of installation instructions we've ever seen for a product of this type. In fact, all you'll need to supply are a fresh pair of GM gaskets and perhaps an hour of free time in order to effect installation on your '99-'12 LS1, 2, 3, 6, 7, or 9 Corvette.

1 BCP’s valve-cover packages...

1 BCP’s valve-cover packages come virtually complete, with all required installation hardware, a quartet of “spider” coil mountings, a jar of Mother’s aluminum polish, and step-by-step color instructions. The coil covers shown here are optional.

2 You will need to supply...

2 You will need to supply your own valve-cover gaskets. BCP recommends the genuine GM items, which are available at your local dealership.

3 BCP’s background in defense...

3 BCP’s background in defense and aerospace contract work is evident in the detailed nature of the supplied instructions and QC documentation. All measurements and clearances are individually verified to within 0.001-inch!

4 For our installation subject,...

4 For our installation subject, we selected a stock LS3 that was slated to be installed in a ’99 FRC. You can think of this look as “production-line utilitarian” (though “ugly” works too).

5a AntiVenom’s Greg Lovell...

5a AntiVenom’s Greg Lovell begins the job by disconnecting the driver-side coil connectors...

5b ...Then unbolts the coils...

5b ...Then unbolts the coils themselves.

6 The coils may then be lifted...

6 The coils may then be lifted off the valve cover as a single assembly.

7a After disconnecting the...

7a After disconnecting the PCV line...

7b ...Lovell removes the...

7b ...Lovell removes the four bolts securing the valve cover to the cylinder head.

8 The valve cover is then...

8 The valve cover is then taken off of the engine and temporarily set aside.

9 This comparison photo shows...

9 This comparison photo shows the inside of the BCP cover (bottom) next to that of the stock cast unit. Note that the former offers more clearance—thanks to its more-efficient baffling—and features supremely rigid integral stand-offs.

10 Next comes the first half...

10 Next comes the first half of what is likely the most time-consuming portion of the job: installing the valve-cover gaskets. Lovell applied a little light machine oil to the bottom of this one to help the process along.

11 With the gasket securely...

11 With the gasket securely in place, the BCP cover is bolted onto the cylinder head.

12 BCP supplies a set of...

12 BCP supplies a set of small O-rings that fit around the coil-bracket bolts and prevent the brackets from marring the valve covers. Here, Lovell pushes them into place.

13 At this point, the coils...

13 At this point, the coils will need to be removed from the stock one-piece bracket; they’ll be transferred to the individual BCP spider bracket assemblies in a subsequent step.

14 Depending on the configuration...

14 Depending on the configuration of your engine’s coils, you may need to install these supplied spacers on the coil brackets. Our LS3 didn’t require them.

15 Lovell next installs the...

15 Lovell next installs the spider coil brackets on the valve cover, taking care to orient the longer mounting legs toward the right side of the cover. (The same orientation is used on the passenger side.)

16 The factory coils are...

16 The factory coils are then installed on the brackets and bolted into place. We topped ours with a set of optional “double” coil covers etched with BCP’s cool skull-and-crossbones logo. (A “single” cover configuration, using one cover for each coil, is also offered.)

17 With the coils reattached...

17 With the coils reattached to their respective connectors, the driver-side half of the installation is complete. Note that if you don’t care for the piratical look, BCP will digitize and apply your own JPG design to the coil covers for an additional $150.

18 Repeat the previous steps...

18 Repeat the previous steps on the passenger side to finish the job. As you can see, the resulting cosmetic improvement over stock is nothing short of remarkable, turning this otherwise-untouched Vette motor into a real conversation piece.

19 A peek down the oil-fill...

19 A peek down the oil-fill hole confirms that our standard-height covers offer plenty of clearance for the stock LS3 rocker arms. BCP also manufactures “tall” covers suitable for use with shaft-mount and high-ratio rocker types.
20 With the project complete,...
20 With the project complete, Lovell unlimbers the polish and puts a show-quality shine on our freshly installed valve covers. BCP offers a billet C6/Z06 fuse-box cover to round out the look, and the company is currently working on a number of other dress-up items for LS engines. Wonder if we could talk ‘em into building an intake manifold...
Fashion plates that we are, we rounded up a set of show-polished BCP covers and recruited longtime coconspirator Greg Lovell--of Seffner, Florida-based Vette tuner AntiVenom--to bolt them onto an otherwise-stock LS3. Although the engine was on a stand at the time of the project, Lovell made sure all of the supporting lines and hoses were attached so as to present an accurate representation of a typical in-car install. (The engine is slated to be shoehorned into a '99 fixed-roof coupe in the near future, at which time we'll snap some follow-up photos of the installed BCP covers.) Follow along now as we dress this LS to kill.