@NarrowEyes,
If you have the chemistry chops to do all that work for zinc powder then count me as impresed! However, Zinc dust is not that hard to find. Check out scienceforyou.net I got a pound of zinc powder 325 mesh for ~$10.
My question is what to use to make the zinc/sulfur mix into a "putty" to pack into the casing? Someone recomended acetone. Would isopropyl alcohole work as well?
An inhibitor was also recommended. Baking soda?
Could I use ethelyne glycol (anti-freeze) as binder/inhibitor?