I haven't reached the stage of putting the suspension brackets on, however from what I read, you need to add some packing behind some of the brackets to bring them out further. Someone will be able to confirm this shortly.
Quite a few people are going via the zetec route, i know that Spud69 changed from a 1.8 CVH to a brand new 2.0l zetec, so he should be able to advice you on that.
Personally I would wait until you have your lights as you might find a perfect pair , to then find the hole you have drilled is too big. You can purchase 7" headlights from ebay for about £46 delivered i think, Handy Andy has some on his car at the moment and they do look good.
In regards to the roll bar, AshG tends to do bulk buys for people looking to get a prebent roll bar, you then just need to add the plates onto the end of it, the rear stay bars and the seatbelt mounting. Due to my height (6'6") the standard roll bar is too short for me, however I only found this out after buying one and putting it on my car, so if you'd be interested in buying it then feel free to send me a PM.
I'm not sure how tall HandyAndy is, be he is pretty short
, however I think he fits fine in his car, although im sure he'll be along shortly to advise you.
Steering rack and mounts can be bought from saturn sports cars (
link), the company is ran by Spud69 and HandyAndy, and if you ask anyone on here, they will happily recommend them. You can also buy them used on the Locost Builders forum, as they pop up from time to time.
Im unsure about the pedal bushes, but I think 3GE components can sell them if you email them.
I think people are just using the standard Sierra master cylinder, im unsure of the hole size though.