Thanks for the advice guys. Clearly there are limitations in ZenCart and I expect with most shopping carts. The multi items multi manufacturers freight estimation looks like one key issue here. The packaging dimensions freight estimation input limitation another key issue. The per item method does not seem ideal either, but probably not a bad freight cost averaging method.
I have set the zone to NSW to get some kind of freight cost averaging happening, as I see my main markets being on the east coast. I've also tweaked the shipping / packaging added percentage weight settings. I've cross checked it against my manufacturers shipping costs and am now getting costs close enough to pass. I can review that when the need arises.
For now I'm keeping it simple. Most of Zencart is working very well for me. I can deal with these more complex issues down the track when required. It's early days yet.


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