I've hit the wall in figuring out a solution to my shipping requirements. I'm hoping for some guidance on how to solve it.
I'm selling fabric and sewing patterns. I've configured zone based shipping for US, Canada & Mexico and All Other Countries. I have 4 tiers based on the dollar value of the order. For US, the bottom tier is $4.60. This approach is fairly accurate for shipping fabric.
My problem is patterns. If a customer orders a pattern along with fabric I'm fine. The pattern slips in the box and goes along for the ride. Trouble arises when a customer orders a single pattern. I'd like to charge a US customer $1.14 for a First Class Mail parcel.
This is where my dollar value zone structure breaks down.
I'm really at a loss of how to fold this item into my shipping rates. Ideally I would like to have a surcharge per pattern that could vary by zone, I would also like it to disappear and not be added on if the order is mixed with fabric.
I also experimented with a weight based approach but my USPS interface didn't seem to work accurately for flat rate boxes. Maybe I need to code these rules myself? I'm really not looking forward to maintaining a weight for every item in inventory.
I've spent so much time attempting to get my current solution working, I'm hesitant to go in a different direction without some advice and a plan that will address my requirements. Please help!
I'm using version 1.3.8 and my development site is www.pinkbypost.com/store




