Danger:
I do have another problem. Not sure why but the shipping module is showing about $4.00 more than what it actually costs to ship an item express.
I just shipped an item Express with a weight of 1lb at a cost of $15.07.
I set up a customer with that same address and added a couple items to make up the 1lb and the module shows a cost of $19.06 for Express and Ground shipping.
Both prices are without tax added.
I know it's just an estimate but $3.99 seems a bit out even for an estimate.
Turn on the error checking for this module. This involves un-commenting a few lines in the code. I've made it obvious where to do this, but I can tell you how if you need.
This will tell you exactly what Purolator is returning as a value.
My suspicion is it's not Puro or my code.
Zencart has a specification where it adds to the calculated weight before it does the request (to account for packing) and/or it adds to the value received to give you a markup.
After turning on error checking, when you do a quote, there will be a comment at the top of the source-code of the page. This will give you the weight and the quote price. Compare these to what you were calculating.
If the weight is different, you have Zencart set to add weight. If the price is different, you have zencart set to add $.
Once you figure out which, there's 2 things to do.
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It's probably the weight tare, in which case go to Configuration/shipping-packaging. There are two lines that are to add a percentage to package tare. Set them both to 0:0.
If it's not the weight tare, I forget where the other setting is, let me know and I'll look for it.
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re-comment the source code so that it doesn't do the error-checking anymore.
Let us know if this works for you.
<edit> Actually, before going through the trouble of playing with the code, just check your zencart settings first to see that both are set to 0:0. If this fails, then play with the code. <end edit>