Ok here is what I seem to be seeing, the usps module appears to be sending all packages as Large in size in the XML string passed to the USPS web service.
There is one odd thing if I set the tare(packaging) to zero weight wich I do anyway, and the percentage increse to 10 percent for large packages the shipping cost actualy goes down and the weight shown is higher. It seems in that situation it is passing "REGULAR" to the we service, very odd indeed.
Im calling a friend who actual reads PHP gonna hard code the web call to Regular.
I cant find anywere in the interface or in the SQL server were large is defined, or oversize for that matter, wich might exsplain why its calculating wrong. There is no information in the database that will it allow it do be done right.
Feel free to tell me I'm wrong, I so want to be )