OK, I guess that BKP have had their say and that would appear to be an end of the matter but I'd have to say that on this issue I disagree with them and that's never happened before. I've generally only used open poled pickups so the only covered pickups I've ever played on a guitar before were some cheap stock pickups on a cheap guitar. It took a battering over a couple of years by me and then a few more years abuse by my sons who both experimented with playing it and when it was sold on to a friend after that there was no damage at all on the pickup covers. He moved it on a few years later and there was still no damage to the pickup covers, though the rest of the guitar was certainly showing signs of wear. The guitar probably cost about the same as one Bare Knuckle humbucker yet apparently the covers were able to last better than this satin black cover. Over the years I've come across plenty of guitarists with covered pickups (non-BKP) who have experienced no problems at all. Unfortunately, as that's my only experience with covered pickups it's all I can base my opinion on so I would therefore have to take the view that it's not just wear and tear. I accept that somebody with more experience of covered pickups will have a far more informed opinion than mine and I was perhaps just lucky but the fact that others on this forum have experienced the same problem with these particular covers and not others in the range would seem to confirm that it's not just wear and tear. I know I certainly won't be getting satin black covers on mine, which is one of the choices I was interested in. I think I'll stick to either burnt chrome or open poled.
At the end of the day it's a judgement call as to when something becomes fair wear and tear and I imagine Tim must have had reasons for the decision he made. I know that high quality customer care means a lot to BKP and he must have known that this decision may cost you as a customer and the potential custom of those you have contact with so I'm damn sure it wasn't a decision he made lightly. I'm sorry you've had a bad experience and, as I've already indicated, I do have a lot of sympathy for your situation but it certainly wouldn't put me off using Bare Knuckle pickups as they're such a great product with such excellent backup but I'll grant you I wouldn't use this cover now.