OK, solved it.

Thanks to Luis's reference to the original rubygems guide, I was able to 
build a simple gem that worked with my Rails 3.0.7 project. So, I 
realized there was something wrong with my use of bundler in creating 
gems.

The problem was that I was not managing the gem's development with git 
after the initial automatic commit with gem bundler. Thus, when I 
executed 'git ls-files' at the command line, I saw that new files, like 
lib/zipcode/config.rb, were not being loaded to the gem specification's 
file list when gem bundler's 'rake install' was executed.

I guess a useful takeaway from this is that Gem::Specification.files is 
a vital part of the dependency loading for a gem...

Grar

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