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My store needed to offer free shipping over 100$ but up to 20 kg of the product weight, coz we sell mattresses too and they are too big and heavy to offer free shipping. So for everyone need to do this with free shipping module, here is a tip how to do it.

In checkout_shipping.tpl.php

Find
if (($free_shipping == true) {

Change to
if (($free_shipping == true) && ($shipping_weight <= 20 )) {

You may also need to add p.products_weight to DB query

i add it coz i need it to display in product info, so it goes like this

$product_info_query = tep_db_query("select p.products_id, pd.products_name, p.products_weight, pd.products_description, p.products_model, p.products_quantity, p.products_image, p.products_image_med, p.products_image_lrg, p.products_image_sm_1, p.products_image_xl_1, p.products_image_sm_2, p.products_image_xl_2, p.products_image_sm_3, p.products_image_xl_3, p.products_image_sm_4, p.products_image_xl_4, p.products_image_sm_5, p.products_image_xl_5, p.products_image_sm_6, p.products_image_xl_6, pd.products_url, p.products_price, p.products_tax_class_id, p.products_date_added, p.products_date_available, p.manufacturers_id from " . TABLE_PRODUCTS . " p, " . TABLE_PRODUCTS_DESCRIPTION . " pd where p.products_status = '1' and p.products_id = '" . (int)$_GET['products_id'] . "' and pd.products_id = p.products_id and pd.language_id = '" . (int)$languages_id . "'");
$product_info = tep_db_fetch_array($product_info_query);