Magento – Possible to split item over 150lbs (ups) into smaller boxes to calculate shipping

Something to consider here is that you may only need to apply some cosmetic front-end changes to the multishipping templates (template/checkout/multishipping/) so that the two orders simply appear as one order to the customer. The shipping.phtml and overview.phtml templates split the two orders, each with a header (Address 1 of 2, etc) and other copy to show it is two orders.

Instead of the default, I might suggest being a little creative on these templates so that the two orders are simply split so they simply appear as two separate line items.

The next bit would be to handle different shipping origins based on the vendor attribute. This could maybe be done in Mage_Shipping_Model_Shipping. You can see right at the top is where Magento is grabbing the shipping origin address from the config and then further down in the requestToShipment() method, the origin address elements are assigned to the shipping request (which I assume would be used later depending on the shipping method called).

That might at least be a direction to head in. Reading over your question and your update I get the impression that you are making this more difficult than is necessary. Always remember that it is generally best to let Magento do what it wants to do, and only modify small bits to handle your specific cases. A majority of what you require is already done in core, so it seems a bit silly to rewrite the multi-shipping components when there may be simpler options.

After spending a lot of time and testing I have the solution which ultimately Magento OOTB provides, Its just a matter for how to use it.

We can ship Bundle items separately. While creating bundle products use the following option.

Along with this, we have one more setting which is based on Clients’s business logic.

The Maximum package weight will always be 150 due to UPS limitation. “Packages Request Type” has two options

• Divide to equal weight (one request): If total cart weight is for eg. 180lb, ups will calculate the rate for 180/2=90lb and if for eg. for 90lb UPS says it will cost $100, the final cost will be $100*2 = 200. i.e. two packages of 90lbs each.

• Use origin weight (few requests): If cart weight is 180lbs with one child product of 50lb and other of 130lbs, UPS will calculate the separate rate for 130lbs and 50lbs package by sending two requests to API and sum them up. For eg. of 130lbs package costs $100 and 50lbs package cost $60 the final shipping cost will be $100+$60=$160. Let me know which is suitable in our case.