Materials: 3mm PVC foam core in black and white. 12-24 x 3/4″ machine screws and nuts. Zip ties and stage line.
Tools: Square, straight edge, tape measure, utility knife, drill, 1/4″ drill bit and a tape measure.
Draw a 23″ hexagon on 3mm PVC foam core and cut out with a utility knife to make a pattern. Drill a 1/4″ hole 1″ on center from each edge located at each point. Trace your pattern, then cut, drill, and repeat.
Make a pattern for a triangle and rectangle connector plate from black 3mm PVC foam core. Then trace, cut, drill and repeat.
Use the rectangle connector plates at the top and on the edges. Use the triangle connector plates in the middle. Hang the first row of tiles off of a bar or strut with zip ties then adjust to be even. Install the first couple rows of tiles working across the top. Then reinforce the zip ties with stage line. Hand tighten the machine screws and nuts on the connector plates. Once the first 2 rows are installed you can run a column down from either side and fill in the rest of the tiles. The tiles can be projected onto, color washed or back-lit. Budget varies according to size. You can get 8 honeycomb out of one 4′ x 8′ sheet of 3mm PVC foam core. Check with your local sign company, plastics company or home improvement store for sourcing the PVC foam core.
Honeycomb tiles are also available for purchase at www.stageskins.com