How to Make Wood Hexagons

Are you bored with your tired old round or rectangular planters, shelves, and desk accessories? Do you want to practice using the bevel feature on your miter saw? If so, creating customized wood hexagons could be your next DIY project.

This project is perfect for beginners looking to enhance their woodworking skills and gain confidence with power tools. Jenn Largesse, editor of House One and Build Basic, demonstrates how to craft wood hexagons using a miter saw. We’ll walk you through the steps to get your creativity started.

Understanding the Geometry

While you may not have thought about hexagons since geometry class, they’re everywhere in nature: honeycombs, snowflakes, crystals—even on sea turtles and pineapples. In part, that’s because they’re very space-efficient shapes that can cover large surfaces using fewer materials. 

In an interior design world full of arcs and right angles, they can also add visual interest to a space. To create your own hexagons, you’ll need to understand their angles and cut them precisely.

Calculating the Angle

Fortunately, all regular hexagons, no matter their size, use the same angle measurements. Just like all squares and rectangles are four-sided figures made up of 90-degree angles, all hexagons are six-sided figures made up of 60-degree angles.

However, remember that you need to cut two boards and make a joint for each angle. That means you’ll need to divide 60 by 2 to get 30. Thus, you’ll set your miter saw at a 30-degree angle to get the sides of your hexagon to fit together neatly.

Why stop at hexagons when you can create pentagons or octagons with the same process? If you want to create shapes with more or less than six sides, follow the same formula shown in the video.

1. Start with 360 degrees (a full circle).
2. Divide 360 by the number of sides.
3. Divide the result by 2 to get the bevel angle.

For a five-sided pentagon, you’d calculate 360 ÷ 5 = 72, then 72 ÷ 2 = 36 degrees. For an eight-sided octagon, you’d calculate 360 ÷ 8 = 45, then 45 ÷ 2 = 22.5 degrees.

The Importance of Precision

In fact, the shapes you can make are limited only by your precision with a miter saw. Accurate cuts are crucial for your shape to fit together properly. Even small discrepancies can lead to gaps or misalignments in the final product. 

Hexagons are a good place to start, especially if you’re using your saw’s bevel function for the first time. Take your time with each cut and double-check your saw settings to ensure consistency. Practicing a few test cuts on scrap wood can be helpful to fine-tune your technique.

Tools and Materials for a Wood Hexagon

This project will create a small hexagonal plant or pencil holder that’s 4 inches tall. Of course, you can alter the size and thickness of the boards to create a hexagon of your desired size. Before starting your project, gather the following tools and materials:

• Miter saw with bevel feature
• 1/2-inch thick 1×4 hobby boards (poplar or pine work well)
• Wood glue
• Painter’s tape
• Sandpaper (120-grit and 220-grit)
• Safety glasses
• Hearing protection

While Jenn uses a Festool Kapex KS120 sliding compound miter saw, any miter saw with a bevel feature will work for this project. To secure the hexagons together, she used 3M painter’s tape and wood glue from Gorilla Glue.

Safety Considerations

In addition to these tools, keep a dust mask handy to protect yourself from sawdust. It’s also wise to have a workbench or a stable surface to cut on. Clamps can assist in holding the wood pieces steady while you work. Keep your work area clean and free of obstacles that might cause accidents. Familiarize yourself with the operation manual of your tools to avoid mishaps.

Keeping your tools in good condition ensures precision and safety. Regularly check the alignment of your miter saw, clean its blade, and ensure all moving parts are well-lubricated. This will not only extend the life of your tools but also provide better quality cuts.

Step-by-Step Guide to Make Wood Hexagons

Follow these steps to create your own wood hexagons:

1. Set up your miter saw by adjusting the bevel to 30 degrees.
2. Clamp a stop block on your miter saw to ensure consistent board lengths.
3. Put on your glasses, mask, and hearing protection, and make the first angled cut near the end of your board.
4. Flip the board, slide it against the stop block, and make the second cut.
5. Repeat this process until you have six identical pieces.
6. Sand the cut edges to remove any burrs or splinters.
7. Arrange the six pieces in a row with the shorter sides facing down.
8. Use painter’s tape to hold the pieces together in this configuration.
9. Flip the taped boards over and apply wood glue to each mitered edge.
10. Carefully roll the boards together, forming the hexagon shape.
11. Secure the final joint with another piece of painter’s tape.
12. Allow the glue to dry completely before removing the tape.

Practical Tips for Cuts

To ensure consistency, always double-check your stop block position and saw settings before making each cut. Using sharp saw blades will provide the cleanest cuts.

Also ensure that your cuts on each board face opposite directions. That is, when you’ve made both cuts, each board should have a long side (which will face out when joined) and a short side (which will face in). In profile, the cut board will have a trapezoid shape.

Assembling the Pieces

When applying the wood glue, use a small brush to spread it evenly across the mitered edges. This ensures a strong bond without excess squeezing. If needed, use extra painter’s tape to hold the shape together during the drying process.

Apply even pressure as you roll the hexagon together, as squeezing could throw off the alignment of the pieces. Allow ample time before handling or finishing your hexagon.

Troubleshooting Common Issues

Since this is a practice project, don’t worry too much if you end up with gaps or misalignments. If pieces don’t align properly when you’re first fitting them together, re-sand the angles carefully to adjust the fit. If you find gaps after gluing, use wood filler that matches your wood type to fill them. Sand the filler smooth once it’s dry. 

Finishing Touches

After your hexagon is fully assembled and the glue has dried, you can further customize it to suit your style.

• Sand the entire piece for a smooth finish.
• Apply wood stain to enhance the natural grain. For a rustic look, use a darker stain or paint your hexagon in distressed tones.
• Paint the hexagon in your choice of colors. For a modern aesthetic, opt for sleek, monochromatic paint finishes.
• Add decorative elements like gold leaf or decoupage.
• Apply a clear protective finish for durability.

Creative Applications

Once you’ve mastered the technique of making wood hexagons, the possibilities for using them in your home are endless. Here are some ideas to get you started:

• Planters: Create unique geometric planters for succulents or small herbs.
• Wine rack: Design a modular wine storage system using multiple hexagons.
• Desk organizer: Craft a stylish holder for pens, pencils, and office supplies.
• Wall art: Arrange multiple hexagons in a pattern for an eye-catching wall display.
• Shelving: Mount hexagons on the wall for unconventional open shelving.

Beyond decorations, wooden hexagons can serve practical purposes. For instance, they can be used to create trivets for hot dishes, or as part of a larger furniture piece. Their modular nature allows for creative stacking and arrangement.

Our Conclusion

Making wood hexagons is a simple yet rewarding project that can elevate your DIY skills and home decor. With just a miter saw and some basic materials, you can create versatile pieces that serve both functional and aesthetic purposes. Whether you’re a beginner or an experienced woodworker, this project offers a great way to flex your creative muscles and produce something truly unique.