I've scoured the forums off and on for about a week attempting to solve this one. There are a few similar threads, but nothing has helped thus far.

I've only got one shipping module installed: Canada Post. None of my products have the "Item ships in its original box" checkbox checked. All my products have their dimensions and weights set in cms and kgs, and the CP shipping module settings match.

I add three products to my cart, 1 of each: (12x14x15), (14x16x17) and (8x17x22). They total 0.966kgs.

I have them here in front of me, and they easily fit in a moderately-sized box of 30x25x20. The Shipping Estimator tells me it'll take 3 boxes to ship these three products from Canada to the US, while shipping the same three items within Canada or to Germany only requires 1 box.

I have called Canada Post about it, and they suggested I configure more boxes to give their software more options that may be "just right" rather than just a few massive "catch all" boxes. I only had 4 boxes configured at the time, of vastly differing dimensions, so they seemed to have a valid point. As of this writing, I've configured all 20 possible boxes in CanadaPost's Sell Online, a number of which are seemingly ideal for those three products, but I still keep getting 3 boxes for US destinations.

While I was talking to CP, they also pointed out an oddity which I'd like to check out before calling them back. Apparently their server is reporting back that I need TWO boxes for this order, but the shipping estimator is telling me THREE. So ZenCart is deciding to split the one box that CanadaPost said could hold two items into two boxes with one item in each. Is it doing that based on some overriding size or weight limit somewhere? In Configuration > Shipping/Packaging, I've set "Enter the Maximum Package Weight you will ship" to "30000" which may mean 30kgs, but probably means 30000kgs. What other setting could I be missing?

If anyone has any tips, I'm about ready to stop reading the same threads and trying the same "solutions" over and over.

Sandy