it is still defaulting to the second US at the bottom of the list for me
Yeah, does the same for me too. Must be somewhere in admin that the default is set. I have a vague memory of that. I'll go spelunking for it.
In the meantime I changed the added lines to this...
Code:
$countries_array[] = array('id' => '38', 'text' => 'Canada'); /* added */
$countries_array[] = array('id' => '223', 'text' => 'United States'); /* added */
$countries_array[] = array('id' => '', 'text' => '--------'); /* added */
That gives me the order and the separator line I want. And it works, except for that default, and I'll go find that now... ... ... ...
In admin/configuration/Customer Details I set Create Account Default Country ID to "none". Interestingly the list now defaults to my separator line, not to the first line where it says "Please Choose Your Country". Now to change (or eliminate) that text, and I'll be happy. ... ... ...
Did that in includes/languages/english.php -- changed it to "Please select...". Brief is good.
I'm happy.
Rob