Wow, you have certainly done your homework!
That said, once you decide on your size of hexagon finished go to your local hardware store and see if they will cut you a plexiglass hexie 1/4 inch smaller than your die cut fabric one. Tell them to be exact!
OR, use some type of harder plastic such as a margarine lid or such to draw your hexie shape the size you want and than just trace. Happy hexing!
