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The weight of the product I am testing is set to:
Weight: 9 (on the product entry page)
Package Class: Large (which carries the dimensions 24 x 16 x 16)

I have 2 of these added to the cart. If it’s doing the math correctly, that would equal 18#. So unless I am setting up the weight incorrectly, it doesn’t seem to be flagging the shipment because of weight.

Even if I test the site with Package Class dimensions of 1 x 1 x 1, it gives me the same error: According to the dimensions you entered, the package is too large to be mailed.

If you feel the Handling fee plugin would be a good solution, yes, I’d like to try it out. Thanks.