Steve I am just running into a few issues with the postal zones myself. I have got the cart running and practically configured without having to resort to additional help, I find I learn the subject better that way. I have to admit defeat on the zones however as the shipping estimator is reporting errant charges. Here is my background. This module has helped greatly with my setup which I am concentrating on the UK only at the moment.

I have all the countries listed and they include, UK, England, Wales, Scotland, N. Ireland, RO Ireland, Isle of Man and the Scilly Isles.

I have the UK zone with everyone in the UK listed except RO Ireland. These places are then repeated in additional zones for their respective areas, England, Scotland, Wales, Cannel Islands, N. Ireland, RO Ireland, and Isle of Man.

OK the Zone definitions, are set up as per the instructions I think
UKZR: Zone 1: United Kingdom, Scotland, England, Wales. all set to "all zones"
UKZR: Zone 2: Scotland, with all the outer regions specified AND because they are also listed in the United Kingdom list there is a duplicate list with the same outer regions of Scotland in the Country "United Kingdom"
UKZR: Zone 3: Isle of Man, Northern Ireland, Isle of Scilly with "all zones"

OK when I use the shipping estimator I get the following:

Country: United Kingdom, State Province: Glasgow - UK Zone 1 and the correct fee.

Country: Scotland, State Province: Glasgow - UK Zone 1 and the correct fee.

Country: United Kingdom, State Province: Bute - UK Zone 1 and the wrong fee.
(the Bute region is in my zone 2 listing with Scotland and United Kingdom countries)

Country: Scotland State Province: Bute - UK Zone 2 and the correct fee.

So clearly there is something wrong with my logic and I would appreciate some input to correct my error.

Naturally I can see where the errors are coming from, but I thought there was some logic looking at the zones when it's conducting the calculations?? I don't really know so I will stop before I make a fool of myself

Thanks in advance.

Nigel