OK, I found the error in #2. It was the 'short' php tags in the comments.
Here's the corrected section (also fixed the EOF):
Code:
            <td align="right" colspan="<?php echo $colspan; ?>"><table border="0" cellspacing="0" cellpadding="2">
             <?php // ====> BOF: USPS.com AutoFill <==== ?>
             <?php require(DIR_WS_MODULES . 'usps_autofill_button.php'); ?>             
             <tr><td align="right" colspan="2"><?php echo "Total Weight is $lbsval lbs. $ozval oz."; ?></td></tr>
             <?php // ====> EOF: USPS.com AutoFill <==== ?>
However, every good answer generates a new question.
When I added in the fix to SO to show me the type of shipping, it also shows the weight and I realized that the AutoFill module is NOT including the tare weight of the container. I had 1 item at 1.9 lbs plus 2 at 0.5 lbs each and a tare weight of 0.5 lbs. The AutoFill mod showed 2 lbs 15 oz while the SO calculation was 3.4 lbs (correct). Hope this can be fixed easily.

Maury