The only place to get a $973 MO near me is WM and the Simon BHN $1K VGCs have not worked there in quite some time for me. Did something change?

It should autodrain IF I have enough funds to cover it, which I did. This makes using these cards that much harder and it's not even for MS. BHN better get their act together and fix this. At Costco, it'll drain remaining amount whether you use it as credit(Visa) or debit(MC/Visa).

One more thing. About a week ago, I was buying a microwave at Walmart. Tried to split it $100 on one MCGC and the rest on another. The first charge did not go through even though I typed in $100. Then, I just tried to pay for the whole thing with one VGC. Declined. WT F!

Nope. It isn't blocked. Used it again at Costco warehouse for pizza. No issues. It's like selective blocks based on retailers or velocity issue even though I was making a "regular" purchase.

I buy MOs at Weis for $479.21 (total $480) and split the payment $200 + $200 + $80. Then I come back 10 minutes later for one more. No problems so far.

New DP
 

New (worse) DP. Tried to split 3 ways as usual but third swipe was not authorized. I assume that it's 2 swipes max from now on. I'll confirm that theory tomorrow.

1) Please provide details on the $ value of the swipes.

2) The total amount allowed in a short (~5/10 minute) period is well document here. It's likely not hard to assume you're exceeding that with three swipes.

I'm aware of the 10-minute rule. New DP, confirmed in the different chains (Giant and Weis):

The new limit is 2 SWIPES. I use Staples $200 VGCs, so the maximum money order I can get is $400 minus MO fee (79 and 89 cents, respectively). If I use a $500 VGC, the limit is still $480 which I reach with one swipe, obviously.

Is this limit referring to Blackhawk Visa gc only?

It's specifically a BHN issue, both VGC and MCGC.

So a $250 BHN gc should work with no issue then, correct? Will my $500 BHN gc be declined if I try to purchase a $499 MO at a grocery store (not Walmart)?

No!; Yes!

Why will there be an issue with using my $250 gc?

You'll want to read this thread; and other related to it.

although i was out of the loop for a while, it's a 'no' likely b/c won't be able to get a MO for $499 with BHN's at grocery store nowadays

I am well aware that the gc cannot be used for over $99 at Walmart. However, I was not aware that this spread to other stores. Someone earlier wrote that a $480 MO could be purchased with a $500 BHN gc. Why would I be unable to buy a $249 MO with my $250 BHN Visa gc?