Trouble with shipping weights / multiple boxes

[Phaylon]

I need UPS shipping to quote shipping based on multiple boxes. I have a clone of freeoptions module running that sets anything over 150 lbs to flat rate shipping of $200. I have that setup to quote shipping on some very heavy items I ship on a pallet with freight shippers. The problem is, whenever someone orders a large quantity of smaller items and their combined weight goes over 150lbs it switches these to flat rate $200.

I have the max box size set to 500 on the configuration>shipping/packaging. When I drop it to 50lbs it solves the problem for smaller items but then allows customers to ship a 300lb product in 6 boxes which is of course impossible. Does anyone have any suggestions? Maybe freeoptions clone isn't the best solution to ship these heavy items...

Thanks,
Phaylon

[kobra]

Google for
zencart advanced shipper

[Phaylon]

I've already looked into that module and from the demo, it isn't very clear on if it would help me. I would prefer to find a solution in the available code before spending $$. Thanks for the suggestion though :)