Shipping options question...

Do you mean the top of the Shopping Cart where it says, for example:

Total Items: 1 Weight: 0lbs Amount: $9.99

yes, the weight is 0 no matter how many ALWAYS FREE SHIPPING products i added.
and of course i have set weight 2lbs to those ALWAYS FREE SHIPPING products

the perunitweight and zone rates does reflect the ALWAYS FREE SHIPPING products' weight.
that's mean the shipping rates calculation is correct, working perfectly now, the only problem is the cart keeping on showing weight = 0lbs
thank you

The shopping_cart is using in the header_php.php

  $totalsDisplay = TEXT_TOTAL_ITEMS . $_SESSION['cart']->count_contents() . TEXT_TOTAL_WEIGHT . $shipping_weight . TEXT_PRODUCT_WEIGHT_UNIT . TEXT_TOTAL_AMOUNT . $currencies->format($_SESSION['cart']->show_total());

You need to adjust that for the Free Shipping weight:

  $totalsDisplay = TEXT_TOTAL_ITEMS . $_SESSION['cart']->count_contents() . TEXT_TOTAL_WEIGHT . ($shipping_weight+$_SESSION['cart']->free_shipping_weight()) . TEXT_PRODUCT_WEIGHT_UNIT . TEXT_TOTAL_AMOUNT . $currencies->format($_SESSION['cart']->show_total());

Note if using the shipping estimator, you also need to customize the:
/includes/modules/shipping_estimator.php

and should use your templates and overrides for that ...

thanks ajeh!! works perfectly.
thank you for your time!!

Thanks for the update that this is now working for you ...