[BCSE]

Try this adpboss. I have this working in 4.0.4 for US and Canada realtime shipping. I tested this for FedEx only as I don't have USPS account or UPS account.

In cart.php After:

x_session_register("cart");
x_session_register("intershipper_rates");
x_session_register("intershipper_recalc");
x_session_unregister("secure_oid");
x_session_register("extended_userinfo");
x_session_register("anonymous_checkout");
x_session_register("payment_cc_fields");
x_session_register("current_carrier");

Insert:

# BCSE

x_session_register("zipcode_estimate");
x_session_register("default_country_estimate");

if($zip_estimate == "clear")
{
      $zipcode_estimate = "";
      func_header_location("cart.php");
}
   
if(!empty($zip_estimate))
{
      $zipcode_estimate = $zip_estimate;
      
      $default_country_estimate= $country_estimate;
     
     if($country_estimate == "US")
     {
      	$count = substr_count($zipcode_estimate,"0") + substr_count($zipcode_estimate,"1") + substr_count($zipcode_estimate,"2") + substr_count($zipcode_estimate,"3") + substr_count($zipcode_estimate,"4") + substr_count($zipcode_estimate,"5") + substr_count($zipcode_estimate,"6") + substr_count($zipcode_estimate,"7") + substr_count($zipcode_estimate,"8") + substr_count($zipcode_estimate,"9");
      	
      	if($count != 5)  //checking for 5 digits
          $zipcode_estimate = "";
      	
    }
	if($country_estimate == "CA" && strlen($zipcode_estimate)!=6)
		$zipcode_estimate= "";
      
      if($mode=="checkout")
         func_header_location("cart.php?mode=checkout");
      else       
        func_header_location("cart.php");
}
if($zipcode_estimate != "")
{
 	$config["General"]["default_country"] = $default_country_estimate;
      $config["General"]["apply_default_country"] = "Y";
     
      $config["General"]["default_zipcode"] = $zipcode_estimate;
      
    
      $smarty->assign("estimate","NO");
} 

# BCSE

Then in skin1/customer/main/cart_totals.tpl Before:

{if $not_logged_message eq "1"}{$lng.txt_order_total_msg}{/if}

Insert:

{* BCSE Begin *}
{if $login}
{else}
   {if $estimate ne "NO"}
        
Enter your zip/postal code to calculate shipping charges.

        <select name='country_estimate'>
        <option value="US">United States
        <option value="CA">Canada
        </select>
        

      <input type=TEXT name='zip_estimate' size=6 maxlength=6>
      {include file="buttons/button.tpl" button_title="Calculate Shipping" href="javascript: document.cartform.submit()"  js_to_href="Y"}
      
      {else} 

Click here to change your zip code

     {/if}
     


{/if}
{* BCSE End *}

You owe me a beer if this works adpboss

Carrie