The HDPMT uses more of that gridded template plastic you bought to put grids on your acrylic blocks (http://paperfriendly.blogspot.com/2007/07/easy-does-it.html). Slide your envelope into the 1/4" slot to ensure that an envelope is an envelope. You also could cut a 3/4" opening to ensure that a larger envelope is not a small parcel.
Don't overlook the services and freebies offered by the PO. Click 'n Ship is as consumer-friendly as it gets, plus it's a great time saver. All kinds of free stuff is available in local post offices, in addition to the USPS site (http://www.usps.gov/).
Happy mailing...
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