I'm looking for a more economical way to send weekly mailers, I don't think we qualify for a bulk rate... just below

Have you checked having circulars inserted into your local Sunday newspaper? You can pick by zone in our city (6 major zones).

Postal rates increase on May 14 and is hitting flat and non-machinables pretty hard. It is going to get a lot more costly to mail flyers.

I publish a monthly newsletter for my bicycle club. Our total mailing is just under the 200 pieces required for 3rd class bulk rates. However, its cheaper for us to pay for 200 pieces and get the bulk rate then pay full rate for 190 pieces.

So run the numbers in your situation.