Why I stopped using flat rate boxes for anything over 3 pounds

I shipped 40 orders out of my garage in Reno over the past couple months and finally did the math on my flat rate box habit, and I was losing about $2.50 per package on anything over 3 pounds compared to just weighing and going by zone. The weird part is flat rate feels cheaper when you're standing at the counter because you skip the scale, but the receipt tells a different story by the end of the month. Anyone else switch off flat rate once they actually tracked it, or am I the only one who was sleeping on the scale this whole time?

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