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  1. In the USPS.php file around line 415 I hardcoded handling cost to so the code reads 'cost' => ($cost+2)); Previously it said something like $ cost + $handling_cost[0]... If you do not need variable handling costs this should work for you otherwise you will need to dig into the code some more to figure out how to get the right handling cost per method etc...
  2. What osc version are you all running. I was able to get the above fix and apply it. I was having problems with the USPS options not installing but that was caused due to my general.php file in admin not having the correct function for multi select. I think tep_cfg_multi* Once I added that it is working - the handling cost do not work - but I was able to hardcode the handling cost...