Hi Phil,
Most people are making their own foils. Balsa sheathed with carbon is probably the easiest way. I sandwich two balsa planks with a layer of carbon down the middle to start with as this gives a hard centreline to follow
I'm producing mine from milled aluminium moulds and while expensive is really the only way to produce them with any meaningful accuracy and these things get fussy at this scale if you are taking it seriously!
Chords are pretty small, starting at 5cm and tapering down towards the tip.
My T foils are just epoxied on with a radiused fillet, although you have to be careful handling them out of the water.
All replies are going up on the group anyway!
Cheers
Mike