Ok, thx Kovid. I've since found a few bits in the conversion pipeline which actually do affect covers such as "Clean" and "MergeMetadata" in the structure section. That calibre_raster_cover stuff just was very weird though, because it does quite a complex piece of work to generate it all in the input plugin and then it gets thrown away by Clean.
I'll keep plugging away to see what else turns up. Since I know I can't reuse much of that code anyway its going to be a case of writing my own logic but just trying to find as many of the edge cases to handle that calibre has built up over the years. And fingers crossed I avoid some of the problems that exit in the current conversion handling that result in orphaned TOC cover entries or pages containing only a broken cover link... well eventually, anyway.
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