There is also various legal gray areas as a lone producer.
For example the ATF can declare anything over .50 unsporting automatically making it a destructive device.
While they might not do so to a larger company that can fight back, if you were to upset them for some reason (politically active, selling 80% finished receivers, etc) they could theoretically just declare one of your one of a kind shotguns a destructive device.
As noted a "zip gun" is far less obvious than you may believe and is entirely subjective in many states where the term applies.
There is no real definition, but rather like demonstrated by you, is just something people think they know.
The real defining characteristic is whether it looks enough like a gun, or resembles some items jury rigged together.
Clearly that is far from a comforting thought, considering making a zip gun can have severe legal punishments even while following all federal laws.
Once again this means the authorities have discretion, meaning you are not really free and cannot upset the wrong people.
This also means it is legally safer to follow an existing design, not play around like John Browning with your own.
FA guns are technically easier to make than semi-auto versions.
This brings up another point. According to the ATF firearms that are "readily converted" into machineguns are machineguns. Even though they are made as semi-auto and intended to be used only in semi-auto.
What is readily converted?
Good question.
One thing appears to be a gun firing from an open bolt, the easiest repeating firearm design. A spring powered bolt with a fixed firing pin strips a round from a magazine, pushes it into the chamber and fires it. Recoil pushes the bolt back and the trigger mechanism catches and holds it there.
The most complex part of such a design is the feeding mechanism, not the firearm action, and anyone with some basic tools could build one.
Yet the ATF is not fond of newly manufactured open bolt guns, and can declare you in violation for building and possessing a machinegun just by making a semi-auto one.
Yet many guns on the market would appear to be "readily converted".
A little tab is sold for Glocks for example that converts them into select fire and can be installed in a couple minutes.
http://www.fss-g.com/description.htm
(and something similar is readily made for many firearms, the FSSG manufacturer obviously just chose to focus on a model used by LEO in large numbers available in the same dimensions in many calibers so the single product maximizes customers.)
Does this mean all Glocks are "readily converted" and therefore machineguns?
No. Why? Because they are a widely owned firearm.
But your custom firearm wouldn't be. So it should be obvious that "readily converted" is really just whether the ATF says so or not.
Guns that have taken over an hour by experts working with the ATF to convert from semi-auto to full auto in a well equipped shop have been declared illegal "machineguns" because they were "readily converted" while guns that can be converted by anyone in a couple minutes are not "readily converted" and therefor not "machineguns".
Less tested territory would be electronic firearms under the same "machinegun" test.
I have thought of a few designs that would be easy to make using readily available electronics.
Yet any firing mechanism that is electronic can just as easily be programmed to fire more than one shot as it can be to only fire one.
Would this make all electronically operated repeaters "machineguns" because they can "be readily converted"?
ATF could say so.
There is more examples but the post is getting long.
So while technically you are free to build any gun federally that is not title 2, what is title 2 is discretionary enough to be of concern unless you are copying pre-existing firearm designs.
Being John Browning in your garage could get you arrested and put in prison.
He lived in another time.
Likewise "zip gun" is discretionary at the state level in many states that have the term on the books.
If it is blued and looks like a gun it is probably not a "zip-gun".
If it is built 10x better, has a barrel and chamber that can withstand 5x the pressure, and is wonderfully modular, but resembles anything you can buy at a hardware store it may be an illegal "zip-gun".
Be sure to make it pretty enough to be less likely considered a "zip gun". Blued with Walnut furniture and nice lines tends to do it. As does copying something that you could just go out and buy.