(1) When you’re adding a new shipping method, make the pricing based on delivery country, weight, or order total and click Continue.

(2) Use a base price of “0.00″ (and select “Yes” to charges based on weight) because we are setting it up to use the weight ranges instead, which is on the next screen.

(3) Taking from your example, say the $2.95 was for anything between 0 and 5 weight units, and the $4.95 was for anything between 6 and 15 weight units. The Overweight Charge Amount should be set to “0.00″ unless you want to charge extra for each weight unit over the maximum allowed weight (15 in this example) for the $4.95 shipping option. Make sure you click the Update button after you’ve entered the “0.00″ for the Overweight Charge Amount before continuing. Then, in the Weight Max field, enter “5″ and then “2.95″ for the Amount field, and click the Add Surcharge button. Do the same for the 15 weight unit option by entering “15″ in the Weight Max field and “4.95″ in the Amount field. When you’re finished, click the Continue button.

(4) A confirmation page will show you the shipping method options that you’ve selected. If you want to create this method and make it available to customers, click the Save button.

I hope this has provided more insight on how the shipping methods work.

From _____ lb. to _____ lb. charge $2.95 shipping
From _____ lb. to _____ lb. charge $4.95 shipping

All the maximums and ranges and surcharges just makes something that should be very simple much more complex than it needs to be, IMO.