1.3.5 shipping estimator calculator problem

After upgrading to new version 1.3.5 the shipping estimator is calculating postage incorrectly using Zones...

In the shopping cart....(with shipping estimator beneath)

1 item with weight : shipping calculates ok (charged)
2 items with weight : shipping ok (charged)
1 item without weight : shipping ok (free shipping)
1 downloadable item : shipping ok (free shipping)

1 downloadable + 1 item with weght : FREE SHIPPING

but

2 downloadable + 1 item with weight : shipping ok
1 downloadable + 2 items with weight : shipping ok

-tried removing, then installing zones and free shipper module again...

scratching my head
any ideas anyone? I can give more information.. but the site is [local]

I cannot reproduce this problem ...

I turn on Zones Shipping ...

I have it set to Weight ...

I add a Download to my cart ... Free Shipping ...

I add a Product with weight to my cart ... I get a quote on the Zones Shipping module ...

Do you have an URL and products_id for these 2 Products?

Thank you so much for trying... my site is running locally at the moment...

I narrowed the problem down to having my downloadable items set with the following options...

Product is Virtual: (Yes, Skip Shipping Address )
Always Free Shipping: ( Yes. Always Free Shipping )

to make the shipping estimator work with mixed items, BOTH the above items need to be set to NO...

(Using zero weight for free shipping items.)