I changed the temp file as suggested and got a much better result.  Sadly I still lost some files.  The temp folder looks like this "C:\TEMP\$$$$$20120220122310_ZeroZipper_temp" .  Various test with zero zipper seem to confirm that the problem is the 255 limit.  Perhaps if "C:\TEMP\$$$$$20120220122310_ZeroZipper_temp" could be shorten to something like "C:\TEMP\Zero_temp" or even shorter it would would not skip any files.

Also I would like to use Zero Zipper on other peoples computers and would not be comfortable changing their temp file location folder.  I feel like I'm asking too much but if Zero Zipper could be revised to deal with my issues it would very much change my life.  I took a USB flash drive and formatted it to NTFS which allows Everything for Windows from voidtools.com to read the USN Journal and thus created a "dummy drive". I'm hoping to put several "dummy drives" on a single USB flash drive.  Since both Everything for Windows and Zero Zipper are portable I dream of having a complete catalog of all my drive in one USB flash.

thanks!