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My company sells a lot of products that hardly weigh anything, and we sell a lot of products that need to go on a freight truck.
I need to set a weight limit for Flat-rate shipping, so the products that go in a small box can be charged one price for shipping.
Is there a way this can be done. (WITHOUT PURCHASING A MODULE).
Sounds like what you need is to disable flat rate and use matrix rates configured to weight vs destination.
Then setup your flat rate with the needed weight limit.
The free version of the matrix rates extension can easily cover this.