Hmm, sorry I haven't updated this in a while. The problems are very random and usually seldom so I've just stuck with it just because I can't do without the project inspector for my classes. Trying to parse through 2000 lines of code to find the argument for a class I wrote 6 months ago is simply not fun. No other editor autocompletes included classes/functions as accurately as Zend.
To answer a question here, yes, I have tried Nusphere and was not impressed. I think it's just the fact that Zend's look & feel has spoiled me.
As far as the crashes, I can keep them under control if I'm patient. My instinct is to control-s and alt-tab as quickly as possible to my browser to check my update. If I wait half a second for the save to complete before alt tabbing it seems to reduce the crashing. I think the crashing is caused when Zend can't connect to the FTP server during a save, it simply doesn't deal well with it and crashes.
Oh, for the java comment, yeah I was off base there. I just noticed that my most unstalbe programs (Zend, Navicat, Eclipse (the java editor heh)) are all written largely in Java. So, to educate myself I dropped 80 clams on Dietel's "Java How to Program" book and dove in. Have to say I now love Java and if I can clear the mental hurdle of event handling I can start writing some windows apps. It's a real nice change from writing for the web.
Welp, that's it for now. Yes it still crashes but I've been able to reduce it and still happily use Zend 60 hours/week. Thanks for all the feedback!