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I think what the issue is .... is that the envelope at some point is thicker than 1/4 an inch. That means it goes box rate. Did you check that box? You should. A pony makes a mailer more than 1/4 inch thick. This may be the reason the costs are different. Even a little Bushwoolie is going to make that mailer more than 1/4 inch at some place in the envelope. I know it doesn't seem fair, but these are USPS rules. Mailers are great but the USPS feels that they should be thin items to go the cheaper rate. I am almost positive that is what they would tell you. I am sure the Post office is losing money all year long with people using the self service and the online system and not completing the description of their item correctly. It is up to you and your own set of values about things like that. I personally check every box they ask me about concerning size. I don't like breaking rules even if no one can catch me.
If you ship an item that is more than 1/4 inch in thickness as letter rate rather than package rate, there is a good chance that your buyer will receive a package marked "postage due" and have to pay the balance for your shipping error. This has happened to me more this year than ever on eBay purchase from sellers who charge package rate ($2.60+) but ship the cheaper letter rate leaving me with a package that I have to pay the mail carrier to collect, so this is a rather sore subject for me.
Pretty much everyone else already covered how I feel.I do have one other thought though. Are letters put through a different sorting system? I'd be worried by lying and falsely marking something too large as a "letter size" it could be damaged or torn if it goes through any different sort of processing.
I do have one other thought though. Are letters put through a different sorting system? I'd be worried by lying and falsely marking something too large as a "letter size" it could be damaged or torn if it goes through any different sort of processing.
At the kiosk at my USPS, I would select large envelope, since it was in a large envelope after all, and shipping was about $1.50-2 to ship a pony. The kiosk was broken this time and I had to talk to a person. They said that it was a parcel basically if it wasn't paper, and that the cheapest would be $2.60 to mail (it was a Bushwoolie, so even smaller than a pony). How much do you think the post office would care if I continue to select 'large envelope' at the kiosk? It's not much of a loss to me, but that would make shipping go up to $3 for every single pony I sell, within the US.