Hexagon style shelves are not an uncommon diy project, the interwebs is flooded with them! So, after studying hundreds of hexagon projects I quickly noticed that mostly everyone was using a tool called a (sliding) compound miter saw. And you’ve guessed it, I don’t own or know anybody with this particular tool. So the challenge of this project was to make a hexagon shelf without the use of such a tool.
So basically a hexagon shelves consists out of six wooden boards with 60 degree edges on both sides. The idea is to 3D-print a mounting block that attaches to the sides of the board, this mounting block is shaped like a triangle so that the adjacent board is mounted at a 60 degree angle. The 3D print has 3 holes (ha! 3D!) in which a screw attaches the mounting block to the wooden board. This way there is no need for an expensive sliding compound miter saw, you just need an expensive 3D printer to do the job!
For more info on the hexagon shelves and other cool projects take a look at my website: http://www.fritsmakesstuff.com/hexagon-style-diy-shelves/
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Print the mounting blocks with 100% infill in the toughest material you have available. Be very critical towards the quality of the parts, in the end they will need to keep your stuff attached to the wall, and that being said, don't overload the shelves with lot's of stuff.
Paintin’ & Sandin’
I made the mistake in this project to cut the wooden boards first and paint them afterwards. Because I wanted to paint only one side of the board I used masking tape to prevent the edges of the board to be painted. Unfortunately, the paint always seemed to be creeping in between the board and the masking tape. This resulted in hours of sanding the edges that had paint on them, painting another layer and sanding all-over again. Next time I would paint an entire board with a couple of coats and then cut the wooden boards to size.
Assembly & Mounting
The hexagons are formed by attaching the mounting blocks to the sides of each board with the use of screws. I made three hexagons from which two were joined (and thus were sharing some of the mounting blocks). I used cardboard cut-outs to get a sense of how I wanted to position the hexagons in the space, eventually I decided to go with this composition and dotted out the necessary markings for drilling.
To mount everything to the wall I cut up an ‘L’-shape aluminum profile into pieces and drilled two holes for the screws that attach the hexagons to the wall.