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when she showed that it could "flex" a bit, I thought of saying "well, then you should refund me the $0.21 surcharge." But I left well enough alone.
Oh, c'mom, have some fun! Take it up the ladder and go after your $0.21 :-)
FWIW, I remember spending LOTS of time talking with various USPS employees & managers when they changed "Delivery Confirmation" to "Tracking" and rewrote those relevant DMM sections.
That whole effort was simply to avoid having to buy those 1/4" thick boxes (cost 38c each, total weight 3 oz) to send at the first class parcel rate and get tracking or signature confirmation (I could now use less expensive photo mailers at 19c/ea and get tracking and/or signature confirmation with a total weight of only 2 oz.)
I obviously value my time at something pretty close to "zero" but it was fun! It was definitely a case of "If you ask 10 people, you'll get 10 different answers" with the USPS.
If you REALLY want to have some fun, go into the PO with a stiff letter and when they try to add a non-machinable surcharge, DEMAND that they show you it fails the letter flexibility test specified by the DMM. Surely if they made the standard something that stupid, they at least provided test equipment to every PO to check letters against, right??? Be up front & tell them you plan to measure the radius & verify that the belt tension is 40 lbs and not something less; they best calibrate the equipment before testing your letter... LOL!