So it you buy a charm pack that says 30 - 5 inch squares. Does it mean that the seam allowence is in the 5" or is it really 5 1/2?

Usually the charm packs are exactly what they say in size...a 5" is a 5". There is nothing set in gold to what is the 'proper' size in a charm. A charm pack can be any size. Majority of what you find in quilt stores is 5" charm packs. There are some free charm patterns at: http://www.fatquartershop.com/ You will see the free pattern to which I made my 2 quilts w/a bit of difference. And, you will also find a 4" charm square table mat. Hope this helps:))Skeat

Thanks Skeat.