Canada Post : Wrong number of Boxes for US Destination

I am having a bit of trouble with the Canada Post module.

• Zen Cart Version is 1.38a and
• Canada Post Module Version is 1.38
• All products have weights(lbs) and dimensions(in) defined
• All products DO NOT HAVE "Ready to ship" checked
• Units are chosen in lbs -> weights and in -> dimension

After logging into the Canada Post Shipping Profile page, I have defined box dimensions and appropriate weight (provided by the customer).

The problem I am facing is that THE CALCULATION FOR NUMBER OF BOX(es) is wrong for US Destination. :(

If I have 5 random items in the cart and try to checkout with an address in Canada, number of box(es) shows up as 1 (apparently was able to find a box that can fit all 5 items) and shipping fee seems pretty reasonable.

However, if I change the address to one in the US, the number of boxes jumps up to 6 boxes thus way more expensive.

Has anyone seen this problem before?

Should the dimension and weight configuration be in metric system?

Here's an example of the problem.

After adding 4 items, the cart shows

Total Items: 4  Weight: 2.125lbs  Amount: $195.00

For a fake customer in Canada, check out process shows:

Customer Name
4807 - 52 Street
P.O. Box 580
Yellowknife, NT X1A2N4
Canada

Canada Post (1 box(es) to be shipped)

Priority Courier, 2007-12-27     $45.37
Xpresspost, 2007-12-28           $32.11
Expedited, 2007-12-31            $17.84
Regular, 2008-01-02              $18.84

For a fake customer in the US, check out process shows:

Customer Name
1600 Pennsylvania Avenue NW
Washington, DC 20500
United States

Canada Post (3 box(es) to be shipped)

Purolator International, 2007-12-26    $110.71
Xpresspost USA, 2007-12-31             $36.60
Expedited US Commercial, 2008-01-07    $24.05
Expedited US Business, 2008-01-07      $24.65
Small Packets Air, up to 2 weeks       $30.50
Small Packets Surface, 2 to 4 weeks    $25.60

Didn't realize that I had wrong version number posted initially...
ZC is 1.3.8a and CP Module is 1.3.8 :(

I emailed Canada Post Sell Online team and got the following explanation.

Basically....

the number of boxes that return from the Sell Online Server
is the total number of boxes for shipping option types.

NOTE: US Shipping includes Small Parcel Services which has a maximum weight allowed of 1KG per box.

Total Items: 4  Weight: 2.125lbs  Amount: $195.00

1 box will be used for express, expedited, and other services and 2 boxes for small packet option.

Canada Post (3 box(es) to be shipped)

Purolator International	$110.71		- only 1 box
Xpresspost USA		$36.60		- only 1 box
Expedited US Commercial	$24.05		- only 1 box
Expedited US Business	$24.65		- only 1 box
Small Packets Air	$30.50		- needs 2 boxes
Small Packets Surface	$25.60		- needs 2 boxes

As seen from the example, Small Packets Option takes a long time and is more expensive.

I guess the solution is log on to the Shipping Profile server and disallow Small Packets options.

Now I have to verify that Canada Post Module actually converts the dimension and weight in inches and pounds before contacting the Sell Online Server.

I must say... Sell Online Team responded very very fast. I am glad that the issue can now be resolved.

thk

Now I have to verify that Canada Post Module actually converts the dimension and weight in inches and pounds before contacting the Sell Online Server.

Did you manage to find this info?

As seen from the example, Small Packets Option takes a long time and is more expensive.

Small Packets Air is actually faster than Expedited USA, and Small Packets Ground is about even for speed. The only thing you are missing is tracking; you also obviously have to keep in mind the weight and dimensional restrictions [L+W+D cannot be over 90 cm, no side can be over 60 cm.] It is actually the one fairly reasonable shipping option Canada Post offers!