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The layup to an extent will depend on your own preferences, but typically on a curvy tank shape, 3 layers as a minimum would hold its shape, and 5-6 layers would be very tough and stiff. No reason why you can't incorporate a layer or two of kevlar if you wish for some impact protection.
As long as you design a overlap to bond the two halves together, then there is no reason why you would need a baffle from a composite perspective. From a fuel delivery perspective is another matter. In car tanks, baffles would be recommended but I am not sure of the necessity for a bike tank.
We do not sell any tank sealers/liners ourselves but there are a few on the market aimed at composite tanks - especially restoration of them. One such product isGTS 1750 which is sold by Caswell Europe.
Warren Penalver
Easy Composites / Carbon Mods - Technical Support Assistant
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