We offer UK recorded/special and courier shipping, quite often an item will weigh more than the set level for recorded/special , ie over 4/10 kg respectively. But courier quote comes through fine
What you get is all 3 quotes, the recorded/special @ 0.00 saying it cannot determine the rate, and then the courier rate @ whatever it works out to be.
We get a few customers select the 0.00 as its still a 'selectable' method. This can be very frustrating explaining to customers why they can't have 0.00 (free) shipping.
Having looked at the 'zone' shipping modules in ../includes/modules/shipping/... I managed to suss a quick hack to remove that shipping methods 'checkbox' if it cannot work it out.
At around line 136 just after:
if ($error == true) $this->quotes['error'] = MODULE_SHIPPING_UKSD_INVALID_ZONE;
Put this line:
if ($shipping_method == MODULE_SHIPPING_UKRD_UNDEFINED_RATE ) $this->quotes['error'] = $shipping_method;
The above is a working example for the new UK Recorded delivrey contrib, but this will work on ANY zone shipping method, just change the 'MODULE_SHIPPING_UKRD_UNDEFINED_RATE' to whatever module you're using..
Hope this helps.
Thanks
John














