The shipping module will only show up on the storefront when the ship-to zipcode is present in the module's configured list.
I have for testing one zone set up with the first 3 characters (Canada) and another with all six, still the only shipping option that appears at checkout is "Customer Pick Up". I have been using this plugin for years with my live site running 1.5.7d and it's working flawlessly.
Some Success! I have a shipping zone created exactly as my live site and once selected, the zipship shipping option doesn't appear at checkout, however if I select "none" as the shipping zone, it does appear, however the shipping rate for the postal code should be $10.00 but it is showing $11.04 regardless if tax class is set to none. The shipping zone I have set is 9999:10.
@allmart, would you post a screenshot of the zipship configuration? Also, what's the site's setting for Configuration :: Minumum Values :: Post Code?