Hanaldo is right.. Laying up with larger sections will be the best for strength. I have to use 2 sections on each side of the surface layer but it is also joined where I add extra strength too. I would say you need to debulk at least twice once with the surface layer then after every 2 or 3 backing layers. As for inserts you can bury them into the pre-preg during lay up and this is a good way to get them deep inside the part and build outwards spreading the load better and not needing to bond them later. 




Not got experience with the material you are planning to use so cannot say how good or bad it would be. But as it seems to be a 245 gram material I would say you will need some areas with quite a few layers to get the strength you need but it is a good thing as you can make many changes in the material orientation to give it strength in as many directions as possible. Mine is also a fuel cell so the tank has a base and carries fuel. The tank base adds a lot of strength too. 

I have been offered a great deal from a composites supplier close to where I live to buy an OOA 245gsm twill prepreg called DeltaPreg GG245, using the DT806 resin system.

Thanks for the reply!

Regarding the layup technique, cutting small pieces is fine, but you will be reducing the strength of the part. On a cosmetic item this normally isn't an issue, but your piece does have a structural element which you are aware of. You can make up for this loss of strength by overlapping the cuts with additional reinforcement. This obviously results in a slightly heavier part. So I think decide on what is going to give you the best result. Laying up in one piece isn't always as difficult as you might expect; and by the same token, laying up in multiple pieces may not necessarily be easier either. 

Hi!