Bout the same here. I use FuturaLtBt at 13 pts. All the efforts I make to get a thoroughly edited text are preserved in PDF. All, except TOCs, which I fix in the PDF itself.
As I create the PDF with the font size I like, I have no need whatsoever for the zoom button or the reflow function. If you follow my "Libro" link, you'll find a sample of how I work. It's in Spanish but will do equally well to get the feeling. I have changed a little my preferences since I made it, but all the books I read are basically just like this one.
This self-edition of the books I read is one of the things I value most of having a Reader, actually.
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