In zoned shipping by quantity (at least there... that's the one I was setting up) I have stumbled across a minor bug, and a minor annoyance.

Bug:
If you create a zone, say, US Continental, then select all states except alaska and hawaii, save that.  OK.
Create a new zone, called US AK HI, USA is no longer a choice for countries.
Expected Behavior:
US would continue to be a choice, because US and Canada could have multiple "Zones" for shipping.  (i.e. Continental, AK, HI, PR)

Annoyance:
I couldn't figure out why I was getting free shipping when I had set up the above zones (the work-around for US not showing up again was to go into SQL and manually add it...)  until I saw in the shipping zone regions "Free shipping Orders Over Amount".  I left that at the default (0), and everything was getting free shipping.
Expected behavior:
Should default to either -1 (not applicable), or a ridiculous number such as 999999

I would imagine that if folks didn't know about that little caveat, they are getting free shipping as well, and are having problems figuring out why.

--Greg