USPS Error Warning: feof(): supplied resource is not a vali

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Rick,
There are several postings on the subject... It will always save you time when you search properly.
Anyhow, the error seems to stem from the "time in transit" option. 
You need to deselect the time in transit option. To do it, you need to access your ADMIN panel, click on shipping, edit the USPS entry and unselect "time in transit".

Remember that for the USPS shipping module to work correctly, you must sign up and be registered on the USPS production server. If you did not do it, you need to obtain a USER ID and password from USPS fist. You do that at http://www.uspswebtools.com/ look for the "REGISTER" link in the body of the text.

here are a few hints I found on one of the forums.

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Here is a summary of what needs to happen for the USPS function. 

You have to sign up for the USPS API service, like you said. Everyone just signs up to get their userid and password. They tell you that gives you access to test against their "Test" Server. You pretty much ignore that here with osCommerce. The purpose is that you code to submit a set of fixed test scenarios (good and error testing) and once you get back the expected results, you're ready for production. 

The problem is that setting in Admin to go to the "Test" server does not do anything within osCommerce and you won't get it to work without a lot of coding, because all the switch does, it seems, is point to the Test Server. So unless you are only sending the "usps Test" data that is in their manual, you won't get it to work. When you change the Admin to "Test" under usps, it just sets the NAME of the server to the USPS test server, but doesn't have anything in there to run the test scripts data that the usps supplies. Everyone pretty much goes straight to production. 

Once you have your user-id and password from the usps, you just call the 800 number to switch your account over to the production server. 

The number is 1-800-344-7779 (7:00AM to 11:00PM ET)

You tell them you are using "Third Party Software" and it's osCommerce. This tells them you didn't code the interface yourself. They will move you over within a day and you'll get an email from them verifying the move with the Production server names. These names should be "Production.ShippingAPIs.com/ShippingAPI.dll" and [u]these are already set up in osCommerce[/u]. So you should then be able to go into Admin and put in your user-id and password and be good to go. If they ask you at usps, you are only using Rate modules, not printing labels (that's what I'm told but I don't remember them asking me). Some people say they get set up within minutes, others had to call back. If they don't tell you that you'll be set up soon and get the email, call back and hope to get someone else. 
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