Zipcode would really only work with a live shipper like UPS or Fedex. I'm testing this mod on a 3.5.11 setup and using just a zipcode with zone shipping charges won't do anything because x-cart has to know the country and state in order to apply you to the proper zone.
I agree the zipcode mask should be greater than 5 for other country zip codes. But I think allowing the user to choose their country/state should give them the most accurate shipping quote.
I'll let you know what I find.
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