Well, as usual, I find the thread rather late and miss out on lots of the fun.
I remember going through all of this stuff, Tim. Let's see. That would have been 44 years ago. I was working with Minor White (I know it is crass to talk about MW, but I guess I'm gonna exhibit my lack of taste), and he had me so completely confused (you think you have it bad; I had to separate "zone" from "zen") that during the year between workshops, I read the original series of AA's books (which I heartily recommend over the later ones even though they are really stiff reading) and worked it out carefully. When MW came back I told him this, and he said something like "well, now you've done it, and so you've got it. No need to worry much about it anymore".
One further thing that he stressed was that the unique characteristic of photography is that it is a continuous tone medium. That is, it is a continuous spectrum of values, as opposed to virtually every other medium. For example, in printmaking, there is either ink or no ink and the eye fills in the grays. Charcoal drawings can also be continuous tone, by blending the charcoal in various degrees over the white of the paper. So, coming from the horse's mouth, I think there is a question really of just what a zone is. We talked about it, and Minor said very clearly that a zone is NOT a fixed value but, in fact, a range of values within that continuous spectrum, divided for convenience in handling. I have not seen mention of that in this thread, but I think it is essential to comprehend that if you are going to come to a real visual sense of the zone. So, instead of talking about the limited number of values that we have, let's recognize that we have really, if not an infinite number of steps on the scale, at least the 256 increments or so that we humans are supposed to be able to identify. From that total range, we slice parts out to make our zones. And of course, the photographic scale differs from the usual art school scale, or the digital scale, in that we have a peculiar curve shape where the blacks and whites are full of subtlety, and the midtones relatively abrupt.
Two years is not enough to really get this in practice.
I usually write way too much, and I'm going to do it again. I'm going to give you a brief synopsis of my own method of testing and analyzing a film, which I can do in an hour or so per development unit. I'm assuming 35mm here, because that is what I'm doing right now, but you can adapt for your own needs.
By the way, when you print your test patches (I wonder how you make them. There is no need for gray cards, etc. except to give you the comparison value for z5.) there is a neat trick to finding just where that black value is. If you are using an enlarger, you know that the center of the field is the brightest part of the projected light. The edges, and especially the corners are dimmer - they are farther from the lens, for one thing, and the difference in the distance amounts to lost light. Put a piece of processed film on the diagonal from the center to the corner, and print it so the film base is just barely visible in the print of the corner part, but merges completely with the black in the center part. This verifies that you are printing long enough, but not too long. Of course you want to be sure that your lens is stopped down far enough to eliminate any cutoff; that would make it too easy! and also would eliminate some of the precision.
I use a wall in a studio on the north side of a building which has north facing windows as a target. This gives me stable light on the wall. The wall I'm using now is white, but it doesn't matter much as long as the hue is fairly neutral. I used to use a garage door. Lens is focused at infinity; it should be out of focus. I start with one zone less than zone 0, then give one stop incremental increases up to 11 or 12. I'll process these strips at various times. On each negative, I write the zone number with a sharpie and print them using the method I describe above to validate my black. The zone 1 separation is hard to see; it should be. If it is too easy, you need to increase the speed; if you can't see it, decrease the speed. Typically, the z2 patch will turn out to be z1, really, because nominal speeds are seldom correct in use. The number written on the last patch where it could be seen ought to be z8, unless, of course, you make z2 into z1, in which case all the numbers change; z9 would be z8 etc. On the z9, you should not be able to see the number; it will be merged into the white. If your ISO rating and development times are right, z5 would look similar to the gray card.
I use a densitometer and plot curves, but always make visual tests as well. I don't want it to be just numbers. I want to see that scale's visual profile, and these prints give a sometimes surprising view of that. I do perform the tests, but otherwise it is not a "system" for me, it is just nature. I don't think much about it at all when I use it. It is pretty much entirely intuitive.
Don't be discouraged, it takes a long time to really make this yours, but if you keep at it, that will happen. I sympathize, though. I remember how much my mind used to hurt when I was learning it.