Hello,
Is that possible?
Do I create a zone for each area - UK, Europe etc within the one Manual Plugin module?
Sure, you'll just have to directly create a manual shipping method for each situation using the "Price" option and the "Zone" option to restrict your shipping method to USA,Canada, or Europe.
You won't have to create a custom zone as these zone are already set.
Can I just add use an arbitrary weight of say 1Kg for each and every product to Make the system work?
Sure, if you don't have any restriction on weight the setting any weight will do the job.
Kind regards,
Mohamed.