ozpost shipping module

[RodG]

If you could please let me know the best way to solve this issue, would be greatly appreciated.

Thanks in advance,

Daniel

Easy to solve. Go to your gift voucher product(s) and give them a weight of 0.001

The problem (for you, and anyone else that is interested) is that the ozpost module isn't (and never has been) made 'aware' that gift vouchers (and other virtual products) are a special case, and need to be excluded from any shipping calculations.
One of the things the ozpost module does (some will argue that this isn't the right thing to do) is ensure all products have a size and weight, and if none are given then the module assigns values. In the case of weights, a value of '0' is simply converted to a value of '1' - and in your case, since you are using 'Kgs' as your scaling factor this is being interepted as 1kg. Therefore, too heavy for the 500gm satchels.

Incidently, the comment I left myself in the code would indicate that I assumed the '1' would be 1gm - So I guess another way of solving your problem would be to change your weight factor to gms instead of kgs. An extra gram isn't going to make any significant effect on postage costs.

My 'rule of thumb' in deciding whether to use Kgs or gms is, if most of the items in the store weigh less than 1kg then use gms. If most of the items in the store weigh more than 1kg, then use Kgs.
If you have roughly the same number of each... toss a coin :-)

Cheers
Rod