What happens if you change the code on FedEx to read:
Code:
// class methods
function quote($method = '')
{
global $shipping_weight, $shipping_num_boxes, $cart, $order;
$fedexexpress_shipping_weight = $shipping_weight;
if (zen_not_null($method)) {
$this->_setService($method);
}
if (MODULE_SHIPPING_FEDEX_EXPRESS_ENVELOPE == 'True') {
if (($fedexexpress_shipping_weight <= .5 && MODULE_SHIPPING_FEDEX_EXPRESS_WEIGHT == 'LBS') ||
($fedexexpress_shipping_weight <= .2 && MODULE_SHIPPING_FEDEX_EXPRESS_WEIGHT == 'KGS')) {
$this->_setPackageType('06');
} else {
$this->_setPackageType('01');
}
} else {
$this->_setPackageType('01');
}
if ($this->packageType == '01' && $fedexexpress_shipping_weight < 1) {
$this->_setWeight(1);
} else {
$this->_setWeight($fedexexpress_shipping_weight);
}
$totals = $order->info['subtotal'] = $_SESSION['cart']->show_total();
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