Originally Posted by M'Lady Leuedaei

Your ideas work fine but let me make a couple of suggestions that will help.
1. Use card stock to make your hexes (I use 90-110 weight). It's a bit expensive but well worth it in the long run.
2. Definitely punch holes in hexes before you use them.
3. I use a chopstick to remove them. I don't have to worry about cutting the fabric or punching thru it.

By the way. . . You are doing an awesome job. I've included a picture of the 1" hexes that I'm working on currently by way of example.