Gentlemen I have found a solution to our aluminum nozzle woes. I was browsing a shop when I stumbled upon this:
Ra Tech Flute and Spring Upgrade. I read it recently on the Ra-Tech site and totally forgot until I stumbled upon it.
I went out on a limb and bought it. After installation and testing I have VERY consistent FPS readings using the aluminum nozzle. I chronoed at 400fps +/- 5 with 0.25s. There were no erratic jumps in FPS either. So looks like this fix is good!! Unfortunately it does cost to get the part, but as of right now I'm very happy to not have to deal with shattered nozzles.
I'm going to fiddle with it some more and see what other results I can get, but right now it works!