I checked the cheapest rates via this link; US Postage Rates

It shows the ecomomy parcel post (surface) should be $US21.50 for up to 3kg?????

Sounds a tad expensive BAW.
I get 2 boar forms, with back boards and other little supplies sent in a huge box - air - for under $50 US.
Sounds like they are makin up the 'discount' with the postal charges. Cant you check it out via the US postal system?

Come to think of it - i bought an object (2.5 pounds), had it sent Fed EX and only paid $80 australian.

BAW,
How can they quote you US$15 for surface mail and then charge US$53? If it's a credit card order and delivery has not yet been made or the credit transaction is yet to be processed (check online through your bank), then cancel the damn order!
Cheers...
Con
PS: Still haven't found K-Hornet dies but damn it I know I've seen some around here somewhere!?!

If you are sending small flatish things then the USPS Global Priority Envelopes are great . Two sizes , $5 and $9 to NZ , and they fit things like books and CD Roms and flatter sort of stuff fine . Not so good for things with edges though , the card is not that strong .
Sounds like you got had there BAW...

Shipping was nominated as DHL surface mail and quoted at placement of the order as $US15.00

Actual charge THEN levied was $US53.75

You obviously didnt discuss the shipping method first now did you . I just had a difference of opinion with an E-bay seller on shipping and handling . He wanted $20 US for s&h on a $9 postage envelope because he charges for his time to find the goods , clean them up and store them in his warehouse . I suggested that shipping and handling applied to the cost of him shipping it to me , not him finding it in the first place , so we parted less than amicably and the deal fell over .
You need to ask first my friend.....