*sigh* Ok ... I'm hoping if I keep posting my progress it might click with someone and I can get this figured out.

New strategy - I enabled "freeshipper" (disabling "freeoptions") with the United States selected as my shipping zone for free shipping. I still have a yellow status but it *looks* like it might be working. I also enabled the Weight 0 = free shipping.

When I enter a free shipping item only in the cart and I select a US zip, etc it give me free shipping. If I select somewhere outside the US I get no shipping options whatsover for my USPS module.

Adding a product that has normal shipping in to the cart with the free shipping item gives me shipping options in and out of the US and seems to be working properly.

So how do I get the shipping calculated for outside the US for the items that are free S&H otherwise?