I deleted all but one rule, the one that should be applying for this test - and I still get a cost to ship that is less than the flat handling fee alone.
Although, even if a rule did conflict, I don't understand how it is possible that if the flat fee is $7 (currently set for testing purposes) - and it's added to every order that the total can ever, under any circumstances, be under $7? I'm looking at one for $6.48 right now.
In each of my rules I have the min quantities and cumulative prices left at 0 - do they have minimum settings? I'm grasping at straws now....
Currently, this test product does have "shipping/buyer's address" checked.
Its weight is set to 4.00 oz, packaging type "box large" and pack cap is set to 1.
The flat shipping fee is set to $7.
Under "Define packaging" all costs and weights are set to 0.00.
I have one rule: Country: US, states: all, currency: all, units 1-1, weight 4.00-4.00, order total: 0.00 or more
Use shipping method: 5 FLAT.
I add that single product to the cart - and I get shipping: 6.48. Should that not say 12? I thought this might be some strange caching - but that's not it either, as I've tried several browsers with the same result.