This is how I made my own Settlers of Catan board game.
First I want to point out that I have never seen a Catan board in person. I've seen what I could on the internet and what's here on instructables. In fact, before I built this board I had never played it with a real person before. I first learned how to play on the Settlers of Catan ipod touch app. I enjoyed it enough that I wanted it to play with my family, so I looked into buying it. Being the cheapskate that I am, I couldn't shell out $50 for a boardgame. And that's just the basic Settlers edition. You could well spend $300+ to get all the expansion packs. So I looked around and found what others had done here and on other sites and decided to make my own.
Step 1: Measure Twice, Cut Once. Sand, Sand, Sand.
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Step 2: Stick and Spray.
I then used spray adheasive to stick the hex pieces to the back of the printout with the smooth side of the hardboard against the paper, cut out and trimmed to the edge of the board and sprayed it with clear spray paint to seal the top.
I used a similar method for the number tokens, adhearing them to heavy card stock (chipboard), then I cut them out using scissors. I laminated the tokens, but because they were so thick, the lamination didn't seal around the edges, it probably would be better just to laminate the paper only with no cardstock.
I also made the longest road, largest army and resource cost cards in Word, using suitable images I found on the internet and laminated them, as well.
Finally I made harbor cards from an image I got online and laminated them, as well.