I am currently testing/using this module. I ran into a missing function error. _convert_zip_code2() was not in uc_fedex.tar_3.gz. I think I know what you are trying to do here. I've worked around this for now.

Also I could not get to admin/store/settings/quotes/fedex without changing a MENU_DEFAULT_LOCAL_TASK in uc_quote. BTW, I am using code directly from the development repository. This is probably why.

Why is 'Shipper #' disabled in the admin interface? Would you mind explaining the process you went through with FedEx to get setup for testing?