ouch! If you don't want to do inset seams and join all your hexagons edge-to-edge like a baby-block quilt, how about turning them into rectangles? You could add a triangle to 4 of the 6 edges, and square it up - the resulting shape will the taller than wide, but you would at least have nice regular rectangles to deal with. The hardest part might be figuring out the size to cut the triangles - they are not 1/2 squares. You need 60-30-90 degree angles on the addded triangles.