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When you say 'gappy' I'm guessing that it was gaps in the tows of fabric itself rather than dry spots or voids in the epoxy?
If the small mould has return edges, then it could just be the way the fabric's been laid into the mould or that your fabric was a bit loosely woven to start with. A 240g twill is usually a bit more tightly woven and stable than most 200g fabrics, so using this might help.
It's always best to try and place the fabric down into the centre first and gently work it outwards towards the edges to help avoid it being pulled apart too much. Making sure it's in close contact with the corners and edge returns before applying vacuum will also help to stop the centre being distorted as vacuum is applied and you do any finally working of the bag into the corners.
As mentioned already, though, if it's a problem with the surface finish, then slowing the resin flow down and leaving the inlet side open for a short while after everything appears to be wet-out should help deliver a perfect surface finish
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