Iv'e seen hexagon shelves before but I wanted to make some with a little twist. I really like the aesthetic of exposed plywood edges. I wanted to make shelves that would highlight that and would also be really strong. This is what I came out with and I am really happy with the results.Now here is how I did it.
First, I should note that I made 3 different sizes of this shelves. The dimension that are specified are for the largest shelve. You can change the dimensions to whatever size you want. I used this dimension because I was working with scrap plywood form my previous project.
Step 1: Glue and Cut in to Strips
I glued 2 pieces of plywood together. The boards where approximately 17 inches by 15.5 inches. (The dimension are not supper critical they just have to be consistent to cut the pieces needed).
I cut the laminated board in to 1.5 inch strips. For this I needed only 9 strips but I cut 10 pieces just in case.
Step 2: Cut in to Smaller Pieces
I set my miter saw to 30 degrees I put a stop block 8 inches from the blade. I started cutting making sure the plies where facing me.
For the dept that I wanted roughly about 4.25 inches, 18 of these pieces are needed.
Step 3: Glue Pieces Together
In order to have strong joints the pieces must be glued in a staggered manner. This way it creates sort of finger joints.
The best way to start assembling is by stapling the first layer/ring together to hold it in place. That makes the process faster and the staples are covered up by the next layer.
Step 4: Clamp and Wait
Once the first layer/ring is stapled in to place then it is time to clamp the following layers.
After that it is just wait for the glue to dry.
Step 5: Sand and Finish
Then it is just a matter of sanding (a lot of sanding) and applying finish. For this I used Minwax's polycrylic in matte. I applied 3 layers with light sanding in between.
Step 6: DONE
Hang and decorate.