Hello everyone. Thought I might give a little update for those who are interested. The zinc on the bolt action stuff is still working well. Mainly, I'm using them as "bore cleaning" rounds at the end of the day after I shoot my lead. Reason being, a zinc boolit is time consuming to make compared to lead. I've taken to casting them with the sprue plate open, them clamping the boolit nose first in my drill press and using a coarse file to remove the excess slag. Takes about 5 minutes per boolit after I cast it. So I just don't make that many as compared to the lead stuff.
Semi auto stuff: Failure to eject and stovepipe jams are just about par for the course. I'm still experimenting with powders and shotshell stuff is showing promise. I was using Winchester AutoComp, but the boolits are so light and move down the barrel so easily that unburnt powder was evident after each shot. Titewad is at least ejecting some of the casings. I just need to go a little heavier on the load and I think I'll be in business. So far, no barrel issues whatsoever. I've put about 50 zinc rounds through my 92f and about 100 down the bore of my Enfield. They are both fine. Enfield loves the stuff. Huge muzzle flash and ballistic crack. Very little recoil. Like a gigantic .22 haha.
Sizing: Running them through a sizer isn't something I recommend. Tried it, boolit got stuck. Luckily, almost all of them come out to spec. The FEW that don't, I use my file and drill press to turn them down a little. Also, drilling a little dimple on the backside of my .38 boolits increased accuracy a lot and, according to the 1/4 steel I was shooting at, increased speed DRAMATICALLY. But, I suppose that's to be expected.