peglegcharlie, I can't help but notice that your question was not fully answered. Specifically, how to create a label without a sale.
There are a couple of ways of doing this, that I know of.
First, you can go to paypal, and do it directly via this link:
https://www.paypal.com/us/cgi-...webscr?cmd=_ship-nowOr, within Auctiva, you can go to your Sales page, and filter your view to see all your orders that have shipped. Find your sale, that you wish to create a 2nd label for, and click the 'view/edit shipping labels' icon. Click that icon, and you'll then see a 'Create new label' link, and a 'Create Similar' link. Clicking either of those links will allow you to create a 2nd label without a sale.