Thanks for the tips number_6. Unfortunately we are constrained to GIG, JFK and RAK, also was told by QF we were limited to max 5 stopovers on OW award (which is a pity given the 35K mileage limit). JFK-LHR is actually on BA2 (only OK'd by QF after checking with a supervisor as my wife and I are both QF Plat - it seemed they would not have permitted this flight on the award otherwise). Thanks especially for the suggestion of CX via HK - will definitely explore that one.

Guy Betsy, in anser to your question there was no charge for the infant apart from the taxes (a little known perk of the QF FFP.)