sorry - the popup estimator does not work either - I got it mixed up with the rates by cart total (on the staging site).
ugh!

Ruled out anything on my side.
FedEx is getting the dimension data, just returning an error for no reason.
DANG!

The request is good:
<?xml version="1.0" encoding="utf-16"?>
<FDXRateRequest xmlns:xsi="http://www.w3.org/2001/XMLSchema-instance" xsi:noNamespaceSchemaLocation="FDXRateRequest.xsd">
<RequestHeader>
<AccountNumber>XXXXXXXXX</AccountNumber>
<MeterNumber>XXXXXXXXX</MeterNumber>
<CarrierCode>FDXG</CarrierCode>
</RequestHeader>
<ReturnShipmentIndicator>NONRETURN</ReturnShipmentIndicator>
<ShipDate>2010-11-18</ShipDate>
<DropoffType>REGULARPICKUP</DropoffType>
<Service>GROUNDHOMEDELIVERY</Service>
<Packaging>YOURPACKAGING</Packaging>
<WeightUnits>LBS</WeightUnits>
<Weight>21.0</Weight>
<ListRate>1</ListRate>
<OriginAddress>
<StateOrProvinceCode>KY</StateOrProvinceCode>
<PostalCode>40213</PostalCode>
<CountryCode>US</CountryCode>
</OriginAddress>
<DestinationAddress>
<StateOrProvinceCode>KY</StateOrProvinceCode>
<PostalCode>40204</PostalCode>
<CountryCode>US</CountryCode>
</DestinationAddress>
<Payment>
<PayorType>SENDER</PayorType>
</Payment>
<Dimensions>
<Length>110</Length>
<Width>6</Width>
<Height>6</Height>
<Units>IN</Units>
</Dimensions>
<DeclaredValue>
<Value>0.10</Value>
<CurrencyCode>USD</CurrencyCode>
</DeclaredValue>
<SpecialServices>
<ResidentialDelivery>1</ResidentialDelivery>
</SpecialServices>
<PackageCount>1</PackageCount>
</FDXRateRequest>


Did FedEx change their API?

I changed that to check to where any dimension exceeds 109inches, it is forced to 109inches.
I need to change the packing formula to one I used for FedEx on another site (cart I wrote from scratch in Classic ASP).
If none of the items are marked "ship separately", then it tries to put them into a virtual "box" with standard size boxes w/leeway for packing