I have been making hexies for years now out of scrap material.
The first thing that I got tired of was making the papers for the hexies by hand. So found a web site that will let you set up the perfect size hexies you want.
**You can go on line at:
http://incompetech.com/graphpaper/hexagonal/ and fill out the numbers to make the size hexies you want. Print several copies.
**Next I take 3 or 4 sheets of typing paper (8.5 x 11") put one sheet of the printed hexies on top and staple the sheets together (one staple in each corner, in the middle of a hexie). This is a good time to use recycled copy paper.
**I unthread both top and bottom threads of my machine. If you have a denim or heavy duty sewing needle replace the needle in your machine with that needle. You can use a regular needle, but you will need to use less paper in your stack.
**Now start sewing (without thread) around all of the lines of the hexies. I usually start with the long rows and then go between for the short rows. When you are finished you will have a lot of hexie papers made and all you have to do is tear on the perferated lines to get an individual hexie. They practically fall apart for you.
I used to cut out the hexies but found that I wasn't accurate enough and some corners would be a teensy smaller/larger and they wouldn't fit together nicely. By being careful and sewing on the lines your hexies come out perfectly.
For the fabric, I either cut strips 1/2" bigger than the size hexie I am using and then cut them into squares or I use scrap fabric.
Either way I pin a hexie to a square piece of fabric (using very small sequin pins) cut off the corners and sew around each corner, folding the fabric as I go. Using the small straight pins helps to keep your thread from tangling up with the needle. If I am using scraps, I pin the hexie to the scrap and eye-balling it, I cut a 1/4" seam allowance around it. When you are through you take the straight pin out and you have a little hexie waiting to be put togher with other little hexies.
If you are making a number of hexies all the same color, I will take a needle and thread and poke the needle through the center of the hexies to keep them all together when I finish sewing them.
I keep my hexie project in a metal lunch box or a make-up bag (the larger kind you can put bottles in. They have enough space to keep your thread, scissors, needles, papers, scrap fabric or squares in them. With all the space you have you can store unused paper hexies, the scrap fabric and the finished hexies in separate plastic bags. You will also have room to keep the straight pins, a pin cushion and whatever else you need to use in your bag.
You would be really surprised at how many hexies you can make while waiting for doctor appointments.