I made mine 84 mm, slightly larger than the standard Catan tile. First, cut your plywood to whatever width hexagon you want. You absolutely must set the saw up so you cut to a stop. but they won't be hexagonal enough that they tile nicely, and a board with gaps all over the place will look crappy. You'll end up with nice looking hexagons. Rip your plywood to the right width, set the mitre saw to 30 degrees, and cut to a line.
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