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Everything I've been reading says death comes within minutes from palytoxin poisoning so I wonder if all of these reports of stinging eyes and numbness, etc are from something else in the zoas.
I would be more afraid of fragging a zoa and getting some fluid in a cut or getting squirted in my eye. I've fragged 200-polyp colonies into 20 frags with no ill affect on my small 40-gallon frag tank but I do know that some are more toxic than others though.
I've had one aqualifter out of two fail on me in the past two years. Anyone ever try using two aqualifters in a series? If one failed you would still have the other one to push the liquid. Two aqualifters with one acting as a back up is still a lot cheaper.
I use a small screwdriver to dig into the rock under the zoas then use a razor blade to separate the polyps from the larger group. Just be careful of polythoa toxin when you cut into the zoas.