Were you defiantly using a T5 gearbox? As that's quite rare for a kit car unless you were running a V8 or Cosworth YB engine? Type 9 is what they normally come with? Length wise - less than an inch I would say.

Understand you won't want a new prop made, although a T5 costs about £350-400 and a Type 9 costs £100. Plus the flywheel set up for a a Zetec to a T5 costs a bit so worth a thought.

A 2.0 litre Zetec uses a 240mm flwyheel, which doesn't fit in a Type 9 bellhousing as they use 220mm clutches.

Chassis mount kit can come from most places, Retro Ford LTD or Alachi are good.

With regards to crossmember - you must have a steering rack crossmember to avoid though? That will dictate the sump clearance, which will dictate the engine mounts and position, which will dictate the size of the prop anyway!

Hope that helps!