Thanks, Lynn! I'll try that again, and surely use it for Priority Flat Rate. I managed to forget that USPS.com was an option.
I checked my notes from several years ago. At that time, here is what I thought:
"Only Express, Flat Rate & Priority!! No Parcels or Flats or First class!"
At that time I was always weighing packages and sending as First Class Package / bubble mailer.
I also tried to squeeze things into padded First Class letters marked "non-machinable" and just thinner than 1/4", but that really annoys the USPS. It was explained to me that no matter how much you pay for "non-machinable" and "hand-cancel only", "THEY" still try to put it through the high-speed sortation / seed crushing equipment because "THEY"are lazy. That causes jams that tear up dozens or hundreds of FC letters.