Rob enjoys answering questions, but putting them here is much better as we will get more input and solutions. Leaks are a nuisance. There are a number fo detectors, but I have not had much luck with them. Etamax has a very accurate vacuum gauge, which changes when you pass your fingers over a hole in the bag or sealant, but it isn't cheap. I have found some tacky tape is better than others. Softness seems to be the difference. You don't need the high temperature stuff, which seems to be less sticky. Start with the expensive stuff and as your confidence grows, get the cheaper. When you are really confident, use packing tape. It would be worth making your first bag oversize and pulling a test on the table, with a blanket or similar to act as a bleeder. No resin required. Cut off and remove the tape on 3 sides after the test.
Feel free to send me photos and i can check out the layout.
Mateo's foam prices are better than I can get here and shipping will be less. I have just had a quote (not from Rudi) for 400 gsm/12 ounce d/bias of $Aus5/sqm. Might be a little less if you bought a roll. The Tuff Stuff looks pretty special.
Make sure you get thick tow. I have ~6 kg rolls of Zoltek 50K material (equivalent to most other manufacturers 70K) for $Aus45/kg. You might also get some roll ends off Ebay.