Mike,
I understand your desire to make all the parts for your project, but this is the one part thats easy and relatively cheap to buy off the rack is carbon tubes. Its going to be highly stressed part, so it needs to be perfect, and you need to be weight sensitive because its hanging off the front of your boat. If you buy the beam tubes, the forespar and the boom, you would save on shipping.

Tubes are the one part I would BUY. Save yourself the headache and call Forte. www.forterts.com

You probably could find someone going south and have them strap it their roof racks.