After upgrading from 3.0.6 to 4.0.3 FedEx realtime shipping rates are no longer being displayed for shipment weights exceeding 150 Lbs although these shipments are setup to be calculated in 50 Lb maximum carton weights… This worked flawlessly in 3.0.6, however, the dreaded “There are no shipping methods to your freakin location” is back on all shipments exceeding 150 Lbs and stops the order in it’s tracks! 
Has anyone else experienced this, or can confirm that it is a broken feature or bug?? Thanks for your assistance!
What's been going on stranger?
I know you have said in the past that this has worked for you but to tell you the truth, I have never gotten it to work properly (still using 2.2.5). If a customer orders a lot of small weight items, if the total weight is more than 40 lbs, it should create a new shipment but it doesn't. If those items total more than 70 lbs (limit on ground order), it throws them into the freight shipping category (70+ lbs). How in the hell did you ever have it working in the first place?
[quote name=‘The Tool’ timestamp=‘1390503068’ post=‘175893’]
What’s been going on stranger?
I know you have said in the past that this has worked for you but to tell you the truth, I have never gotten it to work properly (still using 2.2.5). If a customer orders a lot of small weight items, if the total weight is more than 40 lbs, it should create a new shipment but it doesn’t. If those items total more than 70 lbs (limit on ground order), it throws them into the freight shipping category (70+ lbs). How in the hell did you ever have it working in the first place?
[/quote] How you doin Tool, just been doing alot of forum observing trying to get a handle on the overall direction CS-Cart was heading and hoping the platform would stabilze, change can be a good & even welcomed thing, although not when they occur as rapidly as they have over the last year, just way too many releases over a short period of time. I am hoping that 4.1.x becomes a solid foundation! Regards to splitting heavy shipments into multiple cartons, it has worked flawlessly for us for quite some time, for example we have a product that weighs 1 Lb, a customer adds 500 of these to the cart, realtime FedEx Ground rates would be calculated as 10 cartons @ 50 Lbs/Carton with spot on pricing! To achieve this all I did was set the “max box weight” at 50 when configuring the individual shipping methods, regardless of the weight of the items in the cart, it would just continue to split them into as many cartons as needed. And now after upgrading to 4.0.3 it is broken, so now there is no weight splitting and as soon as the cart reaches the maximum single weight limit for FedEx Ground of 150 Lbs the order process comes to a halt, and it is really pissing me off at this point! 
Doing good. Just waiting for the smoke to clear with all of the versions being spit out with no stability.
I see. You're talking about individual items which can be configured. What if a customer orders 500 different products at 1 lb each? That's where the issue is for me.
I can't give any advise past 2.2.5 because I haven't wanted to waste my time with bugs. I have installed 4.x and imported my store but it did not go well and even screwed up my live site. I manually imported and haven't messed with it since.
[quote] I see. You're talking about individual items which can be configured. What if a customer orders 500 different products at 1 lb each? That's where the issue is for me.[/quote] No problem with this scenario either, in fact it was a very common scenario for us, all items in the cart regardless of the mix/match combination would still split into multiple cartons based upon my “maximum box weight” setting. This has worked perfectly all the way up to version 4.x
Oh, in the shipping methods configuration? If so, I have those set and it still doesn't work. If it's over 70 lbs, it pushes it right to my freight shipping.
As far as I can tell there's no code for multi box splitting in 4.0.3 source code.There is a code for multi box split if particular product has custom shipping settings but that's pretty much unusable.
Admin>Edit Shipping Method>Configure Tab>Max Box Weight So if maximum box weight had an entry of 50 Lbs and 500 Lbs combined items was added to the cart, FedEx/Ups rates would be calculated as 10 cartons weighing 50 Lbs each. As I mentioned, this worked perfectly up to version 3.0.6, now it no longer splits the contents into multiple packages so when the combined weight exceeds 150 Lbs the “No shipments to your location” message occurs because it exceeds the FedEx/UPS single package weight restriction of 150 Lbs! 
[quote name=‘Struck’ timestamp=‘1392390830’ post=‘177482’]
Admin>Edit Shipping Method>Configure Tab>Max Box Weight So if maximum box weight had an entry of 50 Lbs and 500 Lbs combined items was added to the cart, FedEx/Ups rates would be calculated as 10 cartons weighing 50 Lbs each. As I mentioned, this worked perfectly up to version 3.0.6, now it no longer splits the contents into multiple packages so when the combined weight exceeds 150 Lbs the “No shipments to your location” message occurs because it exceeds the FedEx/UPS single package weight restriction of 150 Lbs!
[/quote]
[quote name=‘The Tool’ timestamp=‘1390526716’ post=‘175916’]
Oh, in the shipping methods configuration? If so, I have those set and it still doesn’t work. If it’s over 70 lbs, it pushes it right to my freight shipping.
[/quote]
Hi Struck and The Tool,
Did you guys ever figure out a solution for this? It's driving me crazy at the moment. It's the only thing holding me up from moving 3 storefronts over to CS-Cart from Magento.
Thanks for any advise or input you can provide. :)
Unfortunately no. It doesn't occur too often so I have just lived with it.