Okay ... let's review ...
If I have products from category 3 in my cart I do not see either:
First-Class Mail Large Envelope or First-Class MailRM International Large Envelope**
But when I ship to Australia, I get $12.75 for shipping and on your site I get $15.75 for shipping, which is your additional handling of $3.00 ...
I do see on your site that when shipping to the US I do not get a First Class shipping rate with USPS but I do on my site ...
If you look at your debug logs can you refresh that /logs in your FTP and Zip up again that last half dozen log files and post it?
Also, can you turn on the setting in Configuration ... Shipping/Packaging ... for displaying Boxes and Weight by setting this to 3:
Display Shipping Weight and Number of Boxes?
0= off
1= Boxes Only
2= Weight Only
3= Both Boxes and Weight


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