Thanks for the quick response -

I have products in category 65 and others. I did a few tests to see how it would behave - checking out one product in another category; then checking out one product from 65; then a combined checkout with a product from each category. In all cases I got a media mail option.

Yes, I'm using the current USPS module. I just installed the newest one this morning before I tackled this project.

The last question might get to the problem, I don't know. This is what came back:

/home2/unspeak4/public_html/purchase/includes/languages/english/modules/shipping/usps.php

Line #12 : * @version $Id: usps.php 2014-09-07 ajeh Version K5 $

/home2/unspeak4/public_html/purchase/includes/modules/shipping/usps.php

Line #14 : * @version $Id: usps.php 2014-10-30 ajeh Version K6 $

I actually only installed to modules / shipping - should the same file go under languages / english / modules / shipping as well?

EDIT - Never mind, I see that I didn't install the languages... .php file, but it's a different file entirely with a lot less in it. Going to load it now just in case that's part of my problem...