If you're making it just to send to a few friends, you won't run into legal issues. If you distribute it publicly, SOE has every right to take legal action, as you're creating and distributing derivative works without their consent. Whether you charge for your zone or not has no bearing on their right to take legal action against you.
Under various laws such as the DMCA, SOE may even be able to argue that since the primary goal of a zone converter is to create derivative works of their zones, then the tool itself is illegal. You are effectively asking others to risk their neck creating a tool whose primary objective is to infringe copyright.
Maybe somebody will make one for you. Will it be me? Not just no, but HELL NO!
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<idleRPG> Rogean ate a plate of discounted, day-old sushi. This terrible calamity has slowed them 0 days, 15:13:51 from level 48.
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