You really need to go to the usenet newsgroup rec.pyrotechnics. Go to google groups and find it there. These questions have already been answered if you search through past posts on that group, but I'll give you a quick answer to most of them now anyway:
>I want to make a smoke bomb. What I need to know is, is it safe to melt sugar >to potassium nitrate? If not please provide a correct solution.
Not really. It's one of those things that you can do several times with no problems, then one time, it will get out of control. Especially around open flame, this is inviting disaster. If you do make smoke bombs, make sure that you use them in small (less than 10g) batches when making them, and don't melt them together. Room temperature mixed KNO33 and sugar works just fine. Don't grind the oxidizer (potassium nitrate) with the sugar together in a mortar or anything, just mix them together on a piece of paper by rocking them back and forth. That works very well.
>Is zinc powder dangerous?
Yes. Zinc is amphoteric (capable of being both a base and an acid) and as such, if mixed with nitrates, can cause a runaway reaction unless precatuions are taken to include chemicals to slightly, but not strongly, acidify the material that you're working with. Zinc is very reactive, and burns with a very hot flame. Although you may have no troubles with it and might not even get it lit in some cases, if it does get lit, and it might spontaneously, even mixed with some rather benign chemicals, you won't be able to put it out.
>How do you solidify powders like engine powder into a thick block?
Engine powder? I'm afraid I'm unfamiliar with it.
>Where can I buy sulfur and some other less dangerous chemicals?
I would take a course in chemistry before trying to go get chemicals to mix them together. Alternatively, if you're just interested in pyrotechnics, search out a local pyrotechnics club. Hopefully you don't live in a lame state like California or Maryland where those fireworks are all but illegal.
>Any other experiements I would enjoy? Thanks a lot. I also need sort of a buddy >to help me so I don't burn down my house like my mom thinks.
Honestly, I would try a few things like exchange of iron with copper ions, etc. There are some very interesting chemistry experiments that are decently safe out there. I'd also have a lot of fun making large blue crystals of copper (II) sulfate.
BTW, I've edited your formula out of the thread; we generally don't post formula for pyrotechnic-type devices on this newsgroup.