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Installing Penny Round Tile

We are remodeling our home ourselves, and chose the Merola penny round tile for a bathroom. We made sure the floor was perfectly level, dropped chalklines, dry fit the tiles and used a 3/16" v-trowel with latex mixed thinset applied evenly. The mesh seems to have had some play in it, and because there aren't spacers made for this kind of tile, once we grouted we realized the spacing between the sheets was too wide in some areas, interrupting what should appear to be an even field of penny tile and it just looks terrible. There's no good resource online or in books (or in the tile stores...they just say how hard it is to use these mesh sheets with the round tiles, even for contractors!) We love the look and want to redo the floor, but are afraid we'll have the same less than ideal results. Does anyone have any tips and advice for us? Many thanks!

Re: Installing Penny Round Tile

Have you considered making your own spacers to match the spacing on the mesh?
I haven't done it with penny tile, but it's worked for me in other applications. If you have a table-saw, you could rip them from a piece of scrap. An easier way to do it would be to buy some shims and cut them off at the appropriate width. OR... hardware stores usually sell smaller sheets of balsa wood, which (I believe) you can buy as thin as 1/16".

I know the rounded edges will make it hard to deal with, but if your spacers are thin (like tooth-picks) then it should get your spacing a little closer to what you'd like to see.

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