metal tape suggestion is good. I use metal tapes. but hey... to give advise on the 1 1/2" allowance... YES... you have to or your trusses wont fit... if you make the poles at 30 x 40, your trusses will not extend out to the edge of the headers as they are supposed to. they will stop at the pole edge. I believe this is more important than having to rip steel. I am currently writing a book on pole barn construction if anyone has any hints or tricks... im all ears... this book is a start to finish pole barn guide... so any tricks throw em my way. I might like em... and use em i guess! ha!

Regards,
Mike