[satcruiser]

I recommend the last solution where items are rated as individual items if the total weight exceeds 150 pounds.

For those of us who are using x-cart Gold version 4.1.2 the $cart array definition where you need to add the "weight" definition is in file ../include/process_cart.php

$cart["products"][]=array("cartid"=>$cartid, "productid"=>$productid,"amount"=>$amount, "options"=>$product_options, "weight"=>$added_product["weight"], "free_price"=>@price_format(@$free_price),"distrib ution"=>$product_distribution);

It works GREAT. Thanks