Burt Rutan figured this out in the 70's. with the Varieze and LongEze's.
Tapered airfoils with twist can be made by running hot wires along numbered
templates.
CNC your templates then hotwire the wings in 4 foot sections.
This will probably be too heavy a method for Sport Category craft.

Scaled Composites in Mojave CA  uses a 50' x 20' x 8'  5 axis gantry mill.

http://www.scaled.com/services/cms_mill.html
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