Valid points, I wasn't really thinking about the cleat position in terms of Hansen's style/role however, when taking that into account it does seem unlikely he could have his cleats too far back at all. If anything, the more toe-down pedaling style combined with high seat height might make it more logical that his cleats are quite far forward *Mavic shoes
I remember reading Hansen made them himself.
There is no way to tell how aft they are from the pictures- the first makes them look normal, the second far back, and the others normal as well. Depends how long his toes are. If you remember that those cleats have the center line a bit further forward, then the first picture makes them look actually fairly under the 1st met protrusion. The second boa line from the front appears to be right at his first met, and the center of the cleat about 1cm behind it.
Judging by his bike setup and watching him pedal I'd be very surprised if his cleats were very far back. A rearward cleat position requires a much lower than average seat height to compensate as the foot becomes less of a lever, if I recall from his pro bike video on Cycling News he actually needs a 400mm seatpost just to get his seat high enough. Also, he is a leadout man for Greipel and moving the cleats further back really reduces top end snap and acceleration and he would still need that in a leadout to move quickly through gaps and step on the gas in the last few km.
The shoes would not be hard to make- someone would just have to make a basic mold to get the arch curvature right and then smooth out the footbed area a bit. They could then make a general mold of the foot and then place the carbon in the first mold and wrap it around the foot and cut the carbon accordingly before it dries. Probably easier said than done, but not impossible.