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How would you cut an internal hexagon without a bandsaw?

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Forum topic by LiveEdge posted 02-23-2015 04:40 AM 1239 views 0 times favorited 12 replies Add to Favorites Watch
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LiveEdge

486 posts in 1084 days


02-23-2015 04:40 AM

Topic tags/keywords: jigsaw bandsaw internal cuts gameboard

I have enjoyed making and playing with wooden Settlers of Catan boards. I’m starting to think about version 3.0, but I would like to somehow make the surrounding border of the board out of one piece instead of gluing up a myriad of hexes. If you don’t know what I’m talking about, you can see my previous project below. I don’t have a bandsaw. I do have a jigsaw, but I’ve never felt it is very accurate in the vertical dimension. It certainly doesn’t seem like it would be accurate enough for these cuts which would need to be quite good. Maybe it would actually be good enough since the wood is about 1/4” thick and mounted on another glue-up base. Ideas?

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12 replies so far

View AlaskaGuy's profile

AlaskaGuy

2406 posts in 1773 days


#1 posted 02-23-2015 04:58 AM

Is this what you mean. Made from one piece of plywood 1/4 thick?

Ops I made 8 sides not 6 but it the same idea.

-- Alaskan's for Global warming!

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devann

2201 posts in 2156 days


#2 posted 02-23-2015 05:03 AM

I know this is not what you ask for, but you may get some ideas from it. Here is a table top that I make from a series of half-hexagons and then make a six piece bullnose to surround it. It is also made on a glue-up base.

-- Darrell, making more sawdust than I know what to do with

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AlaskaGuy

2406 posts in 1773 days


#3 posted 02-23-2015 05:06 AM

devann
Nice and interesting table. I like it.

-- Alaskan's for Global warming!

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devann

2201 posts in 2156 days


#4 posted 02-23-2015 05:13 AM

Thanks AlaskaGuy, I posted the pic so LiveEgde might figure something out that I can’t.

-- Darrell, making more sawdust than I know what to do with

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LiveEdge

486 posts in 1084 days


#5 posted 02-23-2015 05:49 AM

Not quite. Look at my precious board and notice the outer edge is made by gluing hexes together. I want to do the same but have it be all one piece.

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devann

2201 posts in 2156 days


#6 posted 02-23-2015 06:44 AM

It looks like your jig saw might be your best option. As thin as the pieces are you could probably make it work. I use a Porter Cable model 7549 jig saw that has a fixed foot, it does a good job of making 90° cuts. But I doubt you want to buy a new jig saw. You may consider cutting out a 3/4” plywood template with your jig saw. True it up. Then copying the shape to the desired piece of wood with your router using your bushings or a straight bit with a top bearing . I’ve never seen a straight cut top bearing smaller than 1/4”. That may be too big for your application.

-- Darrell, making more sawdust than I know what to do with

View Slemi's profile

Slemi

103 posts in 1005 days


#7 posted 02-23-2015 12:09 PM

Cut the shape to aproximately dimensions with jigsaw and the use chisels and some scrap wood cut to 30/60 degrees as helper for paring down to exact dimensions.

I hope You understand what I mean.

View Redoak49's profile

Redoak49

1951 posts in 1452 days


#8 posted 02-23-2015 12:36 PM

I would do it with a scroll saw.

View distrbd's profile

distrbd

2227 posts in 1910 days


#9 posted 02-23-2015 01:26 PM

Router,inlay guide,and a template,is the first thing that comes to mind,you could also try to make a Hexagon rod and slice it to the thickness you want but I haven’t done that myself ,just thinking outloud.

-- Ken from Ontario, Canada

View LucasWoods's profile

LucasWoods

219 posts in 797 days


#10 posted 02-23-2015 03:11 PM

I would do it with a scroll saw as well

-- Colorado Springs, CO

View LiveEdge's profile

LiveEdge

486 posts in 1084 days


#11 posted 02-24-2015 10:40 PM

The answer I went with was to split the outer ring into six pieces, to roughly shape them with the jigsaw, and to use the chisel to shave them to the right shape with a guide block. It worked pretty well. I learned quickly not to chisel down, but to chisel along horizontally. When I was going vertically I knocked one of the triangular edges off. Whoops.

View Jim Finn's profile

Jim Finn

2412 posts in 2386 days


#12 posted 02-25-2015 12:18 AM

What redoak said. A scroll saw.

-- "You may have your PHD but I have my GED and my DD 214"

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