Almost......see......it's still there....hanging out, but just barely, but enough to cut your border. Try making that a 99.4%
Hmm....the shipping estimator, huh? Well, I don't know. I just checked mine, while logged out, and it worked just fine, so something must be wrong, somewhere. Just don't know where. Might try to find another copy of shipping_estimator.php, and compare them with each other. Here's the part of mine that concerns "not logged-in customers. Maybe it will provide you with somethingdifferent from yours, and help resolve the problem:
Code:
// user not logged in !
if (isset($_POST['country_id'])){
// country is selected
$_SESSION['country_info'] = zen_get_countries($_POST['country_id'],true);
$country_info = $_SESSION['country_info'];
$order->delivery = array('postcode' => $zip_code,
'country' => array('id' => $_POST['country_id'], 'title' => $country_info['countries_name'], 'iso_code_2' => $country_info['countries_iso_code_2'], 'iso_code_3' => $country_info['countries_iso_code_3']),
'country_id' => $_POST['country_id'],
//add state zone_id
'zone_id' => $state_zone_id,
'format_id' => zen_get_address_format_id($_POST['country_id']));
$_SESSION['cart_country_id'] = $_POST['country_id'];
//add state zone_id
$_SESSION['cart_zone'] = $state_zone_id;
$_SESSION['cart_zip_code'] = $zip_code;
} elseif ($_SESSION['cart_country_id']){
// session is available
$_SESSION['country_info'] = zen_get_countries($_SESSION['cart_country_id'],true);
$country_info = $_SESSION['country_info'];
// fix here - check for error on $cart_country_id
$order->delivery = array('postcode' => $_SESSION['cart_zip_code'],
'country' => array('id' => $_SESSION['cart_country_id'], 'title' => $country_info['countries_name'], 'iso_code_2' => $country_info['countries_iso_code_2'], 'iso_code_3' => $country_info['countries_iso_code_3']),
'country_id' => $_SESSION['cart_country_id'],
'format_id' => zen_get_address_format_id($_SESSION['cart_country_id']));
}