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Picture of Wood Burned Settlers of Catan Board
I recently decided to make my own Settlers board with the following goals:
- More durable than cardstock
- Prettier than anything I could buy
- Easy to use in low-light venues
- Total cost under $60

I ended up making board from basswood, burning in the artwork and finishing it with acrylic paint and shellac. It took somewhere between 20 and 30 hrs of labor to complete and is incredibly durable, functional and snazzy. If you just make the tiles and purchase game pieces, you should be able to finish in 10-15 hrs.

There are many ways to improve on this design if you have a higher budget and more time. If I were to do it again, I might opt to stain the tiles or use different hardwoods before shallcking or varnishing to provide some more contrast. The colors I chose for the game pieces aren't the best in low light.; shellecked white and yellow, and blue and green are hard to distinguish in low, yellow light. More comments later, but first here's what I used:

Supply list:
- 3 3 1/2" X 1/4" X ~4' basswood pieces (hexes, ports, longest road and largest army tokens)
- 3 5/8" X 3/8" X 3" square dowels (roads)
- 84 1" wooden coins (pips, settlements, cities)
- Shellack (Amber; 2lb cut if you're mixing from flakes)
- Wood burning pencil
- Pencil
- Paintbrush (one for detail, one for large areas)
- Ruler
- Table, Mitre or band saw
- 30/60/90 triangle guide or protractor
- Art work
- Sandpaper

For a complete game:
-2 sets of Settlers of Catan Replacement cards (need 2 sets to play with 5 or 6 people)
-2 6-sided Dice

 
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Step 1: Cutting the hexes and ports

Picture of Cutting the hexes and ports
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cut1.png
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The most important step is the first: cutting out the hexes. Having a nice monodisperse set of hexes is key to having a usable board; minor variations can cause the hexes to leave annoying gaps in the board. I'll go through the steps I used to cut the hexes on a a table.

I wanted 30 hexes for the 5-6 player version of Settlers; you only need 19.

I cut the hexes in two steps. First, I cut the 3.5" board into 3.5"X (3.5*sqrt(3)/2)" ~ 3.5"X3.0" rectangles. The rounding error is small enough that it didn't matter after sanding. See pic 1.

Each rectangle needs for more cuts to become a perfect hex; these cuts are illustrated in the next four images.

First cut:
Set your guide at 60 degrees and line up the block of wood so that the cut enters 3/4ths of the way across the top of the rectangle and exits halfway through the side. Mark the edge of the block on your guide so that you only have to measure this once

Second cut:
Rotate the block by 180 degrees and line up the cut so it once again enters 3/4ths of the way across the top of the rectangle and exits halfway through the side. Mark the edge of the block on your guide so that you only have to measure this once.

Third cut:
Flip the block over and use the first mark on your guide to make this cut.

Fourth cut:
Rotate by 180 degrees and make the final cut.


I also cut the ports and tokens at this step. I cut 14 1.5X1 rectangles, for 12 ports, the longest road and largest army tokens.

Sand all the edges and faces of your hexes. I used a hand held sander with 300 grit for this step.

Step 2: Wood burning the tiles

Picture of Wood burning the tiles
Ports, longest road, largest army and robber - Imgur.jpg
The next step is to wood burn all the tiles and ports. I used a basic wood buring pencil for this with an all purpose tip (e.g., this one). If you opt for a nicer model, this step will go quicker because the pen will hold more heat and stay hotter.

For the artwork you need:
-Hexes: 5x Brick, 5x Sheep, 5x Wood, 4x Wheat, 4x Ore, 2x Desert
-Ports: 5x 3 for 1, 2 for 1 of all resources
-Longest road
-Largest Army

Once I had settled on my artwork, I drew it on the tiles lighty in pencil on the tiles, using a ruler to guide straight lines. I traced all the lines and each edge of the hex of the wood burning pencil. I lightly sanded each surface to remove remaining pencil marks.

I've included closeups of the tiles and ports if you wish to copy them. I used a mix of 6, 3 and 1 fold symmetry so that they would be easier to distinguish since they were all going to be the same color. These have already been shellacked (next step).

Step 3: Shellac treatment

Picture of Shellac treatment
Working with my cat, Toby - Imgur.jpg
I used amber shellac to finish my tiles. If you wanted to stain your tiles different colors, this is the step to do it. You could use any other finish you like.

I wanted the tiles to be two-toned, so I applied two layers of shellac to the areas I wanted darker, then two coats to the entire piece. Use thin coats and allow ~30-60 mins for each piece to dry between coats. 

Step 4: Pips and game pieces

Picture of Pips and game pieces
Pips - Imgur.jpg
I used 1" wooden coins for all the settlements and cities; and 1" pieces of the dowel for roads.

Each player needs:
-5 settlements
-4 cities
-15 roads

I wood burned the edges and both faces of the coins. I painted the pieces with acryllic paint and covered with two coats of shellac. Try to choose high-contrast colors, as the shellac will mute them. I had bad luck with yellow and white in particular; a light grade of shellac would have been better for the game pieces. 

You need 28 numbered pips (2x (2,12), 3x(3,11) for the expansion and 1x(2,12), 2x(3,11) for the original) and a robber. I found Roman numerals easier to draw. The pips also have letters, which I burned on the backside; the order is different for the expansion, so I put two letters on the back rather than make a second set. I won't put the order here since Mayfair might not like that, but I was able to read it from images of the game being played.


Step 5: Settle Catan!

Picture of Settle Catan!
5-6 player game - Imgur.jpg
3-4 Player game - Imgur.jpg
That's everything (I made)! I ordered two sets of cards from Mayfair (need and extra 30 cards to play the expansion) and a set of GameScience dice. Enjoy!
mefca3 years ago
MAN! you beat me to it! ha, i was just working out the details in my head for a woodburned settlers board and then I saw yours. Excellent craftsman ship sir. I especially like how deep the burns go in the wood. It makes it very vibrant.
KneXtreme3 years ago
Very nice! Did you enter it in the shopbot or toy contest???
benjib0t (author)  KneXtreme3 years ago
Thanks! I've submitted it to the toy contest, but haven't heard back yet.
You can enter it into, I believe, up to three contests!
reedz3 years ago
This is gorgeous...

   I've always wanted to make 3d printed/laser cut acrylic version that was able to handle a high amount of stress. This however, gives a much more rustic and handmade appeal.

   Will you be doing anything to surround the borders? In the stock game it comes with the ocean pieces to tie everything together, so it doesn't separate as you play.

   Also, have you considered sending pictures to Mayfair? I'm sure they would appreciate this sort of handiwork.

Game on.
benjib0t (author)  reedz3 years ago
I don't plan to make any border pieces, mostly for lack of tools. These pieces do stay together better than the cardstock ones; if I do anything, I might make a non-slip coated board.

I haven't really thought about sending it to Mayfair... but maybe I will!
totoro336 months ago

So i you said you made:

"-Hexes: 5x Brick, 5x Sheep, 5x Wood, 4x Wheat, 4x Ore, 2x Desert"

but that only adds up to 26 hexes, in one of your pictures you have 30. could you specify how many of each you actually made? because i thought it was 30 for the expansion and 19 for the regular board.

I hope you reply! your board is beautiful!

benjib0t (author)  totoro336 months ago

Ah whoops. counting is hard :/ I meant 6x brick, 6x sheep 6x wood, 5x wheat 5x ore and 2x desert. Thanks!

totoro33 benjib0t6 months ago

thank you!! also how did you stencil your desings for the hexes onto each of them? also could you post pictures of the stencils you used?

benjib0t (author)  totoro336 months ago
Sorry but ive dont have any stencils to share. I freehanded all the art. Drawing the tiles is part of the fun!
totoro33 benjib0t5 months ago

Hi again, could you explain the ports again, I had a hard time understanding how many you made. you said you made

"Ports: 5x 3 for 1, 2 for 1 of all resources"

I your picture you had 12 ports, but you only accounted for 10, because you have: 5x, 3 for 1 ports (which is 5 ports) and then 2 for 1 of all resources (which is another 5). where are the last 2?

totoro33 totoro335 months ago

and im talking about the expansion version not the regular version just to clarify

totoro33 totoro335 months ago

sorry i keep bombarding you with messages! I noticed that you had 12 ports, but the expansion has 11 (from what i counted from this picture: http://boardgameextras.info/wordpress/wp-content/uploads/2011/04/basic-with-extention-board.jpg)

totoro336 months ago

So i you said you made:

"-Hexes: 5x Brick, 5x Sheep, 5x Wood, 4x Wheat, 4x Ore, 2x Desert"

but that only adds up to 26 hexes, in one of your pictures you have 30. could you specify how many of each you actually made? because i thought it was 30 for the expansion and 19 for the regular board.

I hope you reply! your board is beautiful!

Ellie108328 months ago

This is AWESOME! I love Catan and I can't believe how cool this idea is!

Hawkeye_bkj2 years ago
I have been thinking about making one of these lately and thought of a different way of cutting out the hex pieces. Rather than cutting individual pieces, I was thinking of ripping a hex shaped piece of wood then cutting coins out of it, then you are sure to make every piece the same... though you have to have access to larger pieces of wood to do this and depending on what type of wood you want to make it out of, might be rather costly... fortunately for me, I know a guy with his own mill who is more than willing to cut me custom sized wood for dirt cheap.
bsumner12 years ago
This is nice, What do you think about making a hole in the center of each tile to put the number coin into? I am thinking a half thickness tile and a second one laminated to the bottom of it. The top tile with a hole cut in the center and the bottom one without so there is a recess.
Another thought would be to put a layer of felt on the bottoms so that it is less likely to move while playing, would further reduce the need for a border piece.
highjacked2 years ago
Has anyone tried this with oak or birch plyboard? I can't find any shops that sell basswood in that size, or wider, near my area.
KneXtreme3 years ago
Congrats on winning first prize :) Cheers!
depotdevoid3 years ago
Very nice! At first glance, I thought, "Oh, another laser cut project I'll never be able to duplicate." On closer examination, I realized you'd done it all by hand! I'm very impressed!

I've been thinking about replacing my cardboard settler's hexes with something hand made, if I do this may just be the thing!
benjib0t (author)  depotdevoid3 years ago
Thanks! I was actually quite sick of oogling laser cut versions when I set out ot make this one. It ended up being a bit of work, but was really fun and the little imperfections give it a really pleasant aesthetic.

If you try it out, do let me know, I want to see what you come up with :)
Obst Pause3 years ago
Cool version you made there!
What did you do about the resource cards?
I started my own settlers copy years ago, too, but sadly never finished it. But thanks to your efforts I am considering a restart. Due to the lack of money i used thick cardboard(~40 mm), cut that and used a lot of thinned alkyd varnish to make it waterproof. 
Thanks again for sharing yours!
Obst
Stephica3 years ago
Beautiful, I love it!
zrelaxts3 years ago
skiedra3 years ago
Now that took some time and patience. :) . Well done!
phalanx4473 years ago
This is beautiful. It has such a great feel to it. Nice work!