I have no insider knowledge but I would guess the system is much more rigid than you think.
In Geoff Marshall's video, he travelled from
Harrow & Wealdstone (Z5) to Kenton (Z4) on Bakerloo
Northwick Park (Z4) to Kilburn (Z2) on Metropolitan + Jubilee
Brondesbury (Z2) to West Hampstead (Z2) on Overground (Mildmay)
West Hampstead (Z2) to Finchley Road (Z2) on Jubilee
Finchley Road & Frognal (Z2) to Kentish Town West (Z2) Overground (Mildmay)
Kentish Town (Z2) to Archway (Z2/3) on Northern Line
Upper Holloway (Z2) to South Tottenham (Z3) on Overground (Suffragette)
Seven Sisters (Z3) to Walthamstow Central (Z3) on Victoria
Walthamstow Queens Road (Z3) to Wanstead Park (Z3) on Overground (Suffragette)
Forest Gate (Z3) to Manor Park (Z3/4) on TfL Rail (now Elizabeth)
Woodgrange Park (Z3/4) to Barking (Z4) on Overground (Suffragette)
At the end of the video, he checked the journey history recorded on his Oyster card at a ticket machine (which shows the last 8 "journeys"), and was shown (in reverse):
11:07 Harrow Wstn to Kentish Tn West (charge £0.00)
11:31 Harrow Wstn to Archway (charge £0.00)
11:35 Harrow Wstn to [No touch-out] (charge £3.70)
11:49 [No touch-in] to South Tottenham (charge £3.70)
12:04 Seven Sisters to Walthamstow Central (charge £0.00)
12:17 Seven Sisters to Wanstead Park (charge £0.00)
12:25 Seven Sisters to Manor Park (charge £0.00)
12:39 Seven Sisters to Barking (charge £1.00)
I interpret this to mean that whenever you touch out from the system, the system considers you to have made a journey from your first touch-in to your current touch-out location. If the you are within the maximum journey time (MJT) for this specific journey (e.g. 11:31 at Archway), then your journey is updated ("Harrow Wstn to Archway", with no additional charge since the fare to Archway is the same as that to Kentish Tn West), and can be continued later with an OSI. However, if you exceed the MJT (e.g. 11:49 at South Tottenham), then your journey is considered to have been incomplete ("Harrow Wstn to [No touch out]", with the timestamp 11:35 presumably being when a suitably defined MJT ran out), you are charged a maximum fare, and now since you're touching out you also have a second incomplete journey ("[No touch-in] to South Tottenham" at 11:49) with a second maximum fare charged, and touching further with an OSI opens a new third journey (Seven Sisters onward, eventually completed "correctly" with a £1.00 charge).
Since Oyster charging does not actually care about which zones you travel through - rather it cares about whether the pattern of OSIs and pink validators you have touched matches the pre-defined list of alternative fares and if not then it charges the main/default fare (but these fares are indeed set up to try to match what zones you are likely to have travelled through) - I would be very surprised if the Maximum Journey Time depends on anything else than the same list (or whether it depends on route taken at all - MikeWh's
Oyster Fare Finder seems to imply that it doesn't). Also, I would be very surprised if the MJT clock didn't keep ticking during OSIs. This means, for your purposes, that at every touch-out in your journey, you should look at what the MJT is for a journey from your starting location to this point, and make sure that less time than that has elapsed since you touched in.
In particular, when staying within Z1-4, the longest possible journey in the database would be a 4-3-2-1-2-3-4
journey across 7 zones, putting an absolute cap of (on a Sunday) 2h40 on your MJT, regardless of how many zones you've actually travelled through. If your first touch-in is in Z1, then you will never count as having a journey longer than 1-2-3-4 which is (on a Sunday) 2h15.
The "Tram zone" on the map doesn't count as a zone, so won't add to the number of zones acrossed. Trams are charged as buses and if you use the tram then your OSI chain will be broken.
There is no "out of zones" within Z1-4 except arguably Stratford International Highspeed. There is no OSI with Southeastern Highspeed at either end so any journey between St Pancras and Stratford International will be charged as a separate journey and break the OSI chain.