I'm thinking about making carbon fiber wings to order. I'm making a set right now for my 1984 Team Velocity 8255. Should be done with them next week and will have some idea of time and materials.
Construction is carbon fiber/divylnilcell foam core material wrapped in 6 oz. twill cf fabric that is bagged and cured. In the bag the epoxy pulls through the release cloth and breather fabric so it has a rough finish that would have to be sanded. But that's kind of the point to get rid of the excess epoxy. It's only a single layer so you have to be careful sanding.
They are really light and really strong.
I would probably have people send me file folder stock patterns.