It does seem to be working, but I noticed a side effect. For a domestic customer, the FedEx option is showing up on the checkout page. It has no price, its just the text that reads " FedEx (1 x 0.66lbs)" FedEx is only used for International shipping and should never appear for Domestic.
I backed out the and $rates[$i]['module'] != 'usps') or $size == 1 change and it persists, so it was apparently introduced with previous changes.
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