Custom 3D Settlers of Catan board from scrap plywood

Step 3 Hexagons

I thought this step would be easy. Rip your plywood to the right width, set the mitre saw to 30 degrees, and cut to a line. Hopeless. You'll end up with nice looking hexagons... but they won't be hexagonal enough that they tile nicely, and a board with gaps all over the place will look crappy. You absolutely must set the saw up so you cut to a stop.
First, cut your plywood to whatever width hexagon you want. I made mine 84 mm,  slightly larger than the standard Settlers tile. The strip of plywood then needs to be cut to lengths 2/sqrt3 longer than the width, i.e. 1.1547 x longer, so my rectangles ended up 84 x 97 mm. Cut to a stop, which you can clamp to the fence. Cut at least 19 pieces.
Angle your miter saw to 30 degrees; not 30.5 or 29.5, but exactly 30. Cut a bunch of test pieces, and fit together to ensure your angle is exact. Unless your saw is set up amazingly accurately, you'll have to nudge it about from what it reads on the gauge.
Mark the center, then set a stop so your angle cut precisely trims off a 30 deg triangle (see picture). Again, you'll have to fiddle a bit to get it exactly right - sub-millimeter accuracy is in order here.
Cut all the corners off against the stop. If you don't want the tiny triangle to go flying, wait for the saw to stop spinning before you lift it. Repeat process, trimming four triangles off each rectangle, at least 18 more times until you have 19 perfect hexagons.

Comments

[RedBeardatXMission]

(removed by author or community request)

[thepelton]

I prevent kick back on cross cutting with a table saw by screwing a long cheap board to the cross cut guide which will support both pieces of the wood before and after cross cutting. I also wait until the blade is stopped before reaching for the wood, to save my cut wood pieces, not to mention my fingers.

[EmmettO]

 I've taken shop classes and I regularly cut without any guards in place. Knowledge and training does not ensure adherence to that training.

Now excuse me as I sit too close to the TV and then later I've got a running with scissors engagement to go to!

[Jayefuu]

That wasn't the most tactful way of saying that....

[makendo]

Don't panic; the guard, anti-kickback devices, riving knife and pushstick are all out of shot. You can see them all in place here. 
For those of us less experienced than Redbeard,  en.wikipedia.org/wiki/Table_saw has lots of sound safety exhortations.