ode Yeah once you get even 1/4" over 48" UPS charges a $15 surcharge! The shitty thing is that the boxes which are sold as 48x4x4 are actually about 48.25"x4.25"x4.25" - the 48" and 4" are the INNER dimensions! So if they ever measure that box, which they will always do at the counter when you buy the label in a UPS store, it'll cost you $30 instead of $15. And if you print a label online but lie and say it's just 48", if they happen to audit it and measure they'll hit your credit card for the additional amount and you'll get a notice in the mail for the adjustment. Sucks balls.
But USPS doesn't have a length surcharge, so shipping something longer than 48" is almost always going to be cheaper with USPS.