In response to the original question, use a braided sleeve (such as this )
https://design.sunsetrc.org/tubing/images/tube.jpg
to do away with the bump from overlaps. Plus it is much easier to lay-up, has no seam (and hence stronger) and can be tailored to fit different size tubes, along with more, or less strength in one direction. (by changing the angle of the braid in relation to the tube.
Kevlar is in fact very useful in most rocket applications. I agree a full Kevlar airframe is a waste of time and money. Rarely is a full aramid or carbon structure worth the cost and time involved. But you have to look at where rockets get damaged, and subsequently how they get damaged. I'd say more than half of rocket related damages occur on landing, more than likely from a) non opening main in dual deploy, b) undersized chute to begin with, c) hitting something much harder than the normal ground (rock, pavement, etc..)
All these are "impact" related damages, with the majority consisting of point loading during impact. Hence the use of composites is such a benefit, because they tend to excel in both these areas. Aramid (or Kevlar) especially, because it is so "strong" (regardless of direction). Again the benefit of composites. Any fiber+epoxy is defined as being a continuous fiber Polymer Matrix Composite(PCC).
As a result, the fibers take the brunt of the loading, from whatever direction it comes from. The epoxy (or Polymer used) serves as a medium to transfer the force to the fibers, along with keeping the general shape of whatever the part might be. How does this relate to rocket airframes ? Kevlar has a much greater tensile strength than that of glass or carbon. So ideally, all the force applied perpendicular to the airframe, will be transferred into a parallel force down these fibers. Ideally, being if your laminate is strong enough to resist the initial loading without simply breaking.
So Tensile strength needs to be in your vocabulary when dealing with rockets.
I was under the same impression until a few months ago, when I was involved in doing a finite analysis of composite structures for a small UAV project here at school. Plugging in all the relative strengths and modulus for the particular fiber we were using (Toray T700) and in relatively low speed, frontal crashes (10-15 m/s) we discovered we were significantly overloading our desired combination of 2 layers of 0-90 lay-up carbon. Hence we added a safety layer of kevlar in-between our two layers of carbon.. And all was good.
We ended up crashing this UAV, and our extra effort in finding a worthwhile kevlar fabric to use and integrating it into the airframe paid off wonderfully. Our airplane crashed due to tip stalling on high speed, low level high g turn. A wing hit, the uni-carbon on the wing buckled in some areas, and broke in others. Forward fuselage then hit, and our telemetry said hit with a force of 14 Gs.
F=MA Our plane weighed around 100 N, (22 lb) so ~140 m/s2 (14gees) times 100N is a pretty hefty impact force.. Much greater than we had ever planned for (and we planned to crash). About 2 inches of the forward fuselage cracked, and after that the carbon layers on both sides of the kevlar cracked completely off the kevlar for a good 12. The kevlar stayed intact during the crash, and hence saved our motor and expensive prop from damage, and made repair extremely easy.
So after all that jibbersh, Kevlar is really good material to use, although not on its own. Its a low modulus material, so isnt stiff. So use it as a reinforcing aid, not as a structural material. There are some good charts, and data here too:
https://www.azom.com/details.asp?ArticleID=984#_Fibre_Type_Comparison
As for sanding the laminate, because composites distribute the stress effectively over the top and bottom layers, sanding is usually not a good idea.. Although for rocketry applications, airframes are usually so overbuilt as it is, sanding the laminate may be a worthwhile idea because it reduces the weight.. Plus hand lay-ups have a large layer of excess epoxy on the surface lessening the chance youll ever get to the fibers.
Nick Anderson
https://www.calpolydbf.com
https://design.sunsetrc.org