You could try this Order Total module on post #14:
http://www.zen-cart.com/showthread.p...ight=insurance
with the current USPS October 30, 2014 K6 update:
http://www.zen-cart.com/downloads.php?do=file&id=1292
This does overwrite the file:
/includes/modules/pages/checkout_shipping/header_php.php
and you should ignore the USPS K3 shipping module that is in that Zip file for the optional insurance ...
This will give the Optional Insurance amount the exact quote from USPS for insurance based on the USPS shipping method that the customer selects and give the customer an option to Opt-out of the insurance on the checkout_payment page ...
It requires no SQL changes to the database ...
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