From Forgeworlds site, [URL="http://forgeworld.co.uk/canadafaq.htm"]in regards to international shipping[/URL]: "Orders of £250.00 or more will be shipped by Express Delivery for the same cost as standard delivery"
Free shipping is only within the UK unfortunately, and as they are a UK based company they're probably free to advertise as such.
Also the problem with the molds is that they have been re-cast so often the master is wearing out and the general quality is slipping as a result. They would need to make a new master sculpt to fix some of the problems - I've even heard the master Thunderhawk was damaged so it is being molded off a casting, so is of much less quality, but that may not be true.