FedEx shipper and free shipping

possibly ... in PM would be best

Two things should be done ...

1 get the latest FedEx version from numinix.com so that you are current

2 customize the file:
/includes/classes/shipping.php

with the code in RED to manage your Always Free Shipping products:

  function calculate_boxes_weight_and_tare() {
    global $total_weight, $shipping_weight, $shipping_quoted, $shipping_num_boxes;

[B]// Always Free Shipping added back except for US 48 plus DC zone_id = 21
// bof: allow 1 zone only for Always Free Shipping
    global $db, $order, $cart;
        $valid_zone_id = 21;
        $check_flag = false;
        $check = $db->Execute("select zone_id from " . TABLE_ZONES_TO_GEO_ZONES . " where geo_zone_id = '" . $valid_zone_id . "' and zone_country_id = '" . $order->delivery['country']['id'] . "' order by zone_id");
        while (!$check->EOF) {
          if ($check->fields['zone_id'] < 1) {
            $check_flag = true;
            break;
          } elseif ($check->fields['zone_id'] == $order->delivery['zone_id']) {
            $check_flag = true;
            break;
          }
          $check->MoveNext();
        }

        if ($check_flag == false) {
          $total_weight += $_SESSION['cart']->free_shipping_weight;
        }
// eof: allow 1 zone only for Always Free Shipping
// Always Free Shipping added back except for US 48 plus DC zone_id = 21
[/B]
    $this->abort_legacy_calculations = FALSE;

Then, where I am using zone_id 21, you use your zone_id number for your US 48 zone ...

Now what will happen is:

Only Always Free Shipping Product in Cart
A. US 48 sees ONLY Free Shipping
B. Anyone outside the US 48 plus DC sees ONLY the FedEx based on the weight of the Always Free Shipping Product

Always Free Shipping Product in the Cart and a Regular Product
A. US 48 sees ONLY the FedEx but the weight is only for regular Products NOT marked Always Free Shipping
B. Anyone outside the US 48 plus DC sees ONLY the FedEx based on the weight of the Always Free Shipping Product AND the weight of the Regular Products