USPS - need custom markup option

I could use some help with our USPS module. I'm posting here because this just started happening in the last couple months.

we are getting this email:
-----Original Message-----
From: [email protected]
[mailto:[email protected]]
Sent: Monday, March 23, 2009 7:33 PM
To: [email protected]
Subject: Debug: USPS rate quote response

<RateResponse><Package
ID="0"><Service>EXPRESS</Service><ZipOrigination>80908</ZipOrigination><ZipD
estination>55119</ZipDestination><Pounds>3</Pounds><Ounces>0</Ounces><Co
estination>ntai
ner>None</Container><Size>REGULAR</Size><Machinable>TRUE</Machinable><Zo
ner>ne>5
</Zone><Postage>30.55</Postage></Package><Package
ID="1"><Error><Number>-2147219434</Number><Source>DomesticRatesV2;clsRateV2.
ValidateWeight;RateEngineV2.ProcessRequest</Source><Description>First Class mail must weigh 13 ounces or less.</Description><HelpFile></HelpFile><HelpContext>1000440</HelpContext></
Error></Package><Package
ID="2"><Service>PRIORITY</Service><ZipOrigination>80908</ZipOrigination><Zip
Destination>55119</ZipDestination><Pounds>3</Pounds><Ounces>0</Ounces><C
Destination>onta
iner>None</Container><Size>REGULAR</Size><Machinable>TRUE</Machinable><Z
iner>one>
5</Zone><Postage>9.05</Postage></Package><Package
ID="3"><Service>PARCEL</Service><ZipOrigination>80908</ZipOrigination><ZipDe
stination>55119</ZipDestination><Pounds>3</Pounds><Ounces>0</Ounces><Con
stination>tain
er>None</Container><Size>REGULAR</Size><Machinable>TRUE</Machinable><Zon
er>e>5<
/Zone><Postage>6.94</Postage></Package></RateResponse>

This could be a a TARE weight issue as we are using percentages.
the problem is our weights are all very different from ounces to pounds. our tar weight for small to medium is 75:0

Incidently it looks like our xml email here is also kind of messed up.

Our system setup :
Zen Cart 1.3.8a
Database Patch Level: 1.3.8

so I think we are up to date. The email seems to indicate someone is trying to order a 3 lbs product using first class. That certainly violates the 13 oz rule. I'm sure this is something I'm doing. What does everyone think?
agrapha

Your Tare says add on an additional 75% of the weight of the order ...

Is that what you want to do?

The client says he set this for 75% of the price to the order.

So that being the case, it would explain why a product weighing 10oz could select first class then during the order process the usps rejection for the order weight (about 1.75 pounds with added tare) kicking off the errored email.

Here is what he is really trying to do. He would like to add 15% to the cost of the item for shipping and handling with a max of $5.00.
So 10 dollars would fetch an extra $1.50 to pay for boxes, postage, and shipping; however $100 item would only fetch a max of $5.00 for shipping and handling.

Can you give us some ideas how to set this up?

It looks like you should be able to use Table Rate for this, as follows:

33:1.5%,10000:5

That will charge 1.5% up to $33 (4.95, as close as I could get to the $5 max) then $5 up to $10,000

I haven't tried this, and it's possible the % will only work as the last item in the listing.

If you need to use the USPS shipping module you could customize the code where the Handling fee is added and calculate the additional charge and add it to the cost for each of the quotes ...

Excellent mamasylvia and Ajeh,
I'll try both ideas. His traffic is still low enough I can kinda test.

First up is the Table Rate test.

Second I'll need a little backup on. Ajeh, what is the file path for the usps shipping module? I have a little bit of php skill so I'll take a look and see if the code scares me like a ghost...

Thank you all for your suggestions.

agrapha

All shipping modules are located in:
/includes/modules/shipping

with their language files in:
/includes/languages/english/modules/shipping