I use the larger Fiskars punch, bought on sale at Joanns, with the thin cardboard subscription cards that come in magazines or other paper of that thickness that comes my way.
Bonnie Hunter has a great tutorial for cutting and sewing hexies
http://quiltville.blogspot.com/2010/...-tutorial.html
Have not tried this, but here's one way to finish your project
http://badskirt.blogspot.com/2010/05/tutorial-finishing-you-hexie-quilts.html
Years ago I said I'd never ever do these and now I'm hooked
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Good luck and have fun...you may find them as addictive as I do.