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Columbus do a 1" carbon fork, Ceeway do them at a good price - check if it comes with a bung (can't use star nuts on carbon). Almost no-one does 1" ahead stems anymore, because you can use a 1 1/8" stem with a shim on a 1" fork, so why make a specific one for the three people who want them? Sometimes you can get one on ebay. Miche do a perfectly serviceable 1" threadless headset for £30ish. You can convert a threaded headset to threadless by striping out the threads. Don't forget some carbon assembly paste before clamping up the stem.
(I know all this because I just built a bike with a 1" threadless carbon fork)
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West Systems 105/205 epoxy with 404 high density filler where it was gappy. It's okay to work with, and the filler powder lets you get the consistency you need/want so it doesn't run everywhere. I've sat on it, and it seems pretty stable - have yet to go for a test ride. Coldharbour is the expert on this. If I had a lathe and mill I'd be building a stainless/carbon homage to ALAN. Not sure if any OTS lug sets would be suitable... might have to have a look, seeing as I now have a spare 753 back-end and no project on the go
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Gone. Happy travels, Lazysuperhero.