I used my Accucut to cut the hexs. I used the middle cutter, 1 1/2" I think. Then I basted them onto the cardboard hexs & starched them, took the cardboard out & then stitched them together. It took a little more time, but I didn't have to contend with the bulkyness of the cardboard when I stitched them together & the starch made them hold their shape really well. Finished size of each hex is 1".