This project was built and designed by Mike Montgomery from Modern Builds. It’s a creative and cost-effective flooring solution that uses hexagonal plywood tiles to add visual interest and warmth to any room.
Mike walks through the full process—from cutting the plywood to laying down the intricate pattern—all using basic shop tools and straightforward methods. The result is a stunning floor that’s both functional and stylish.
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Why Plywood Flooring Makes Sense
Plywood offers several advantages over traditional hardwood. Its layered construction makes it more dimensionally stable, so it doesn’t shift as much with changes in humidity or temperature.
That stability is key in environments like basements or unconditioned rooms. And since plywood is widely available, it’s also more affordable and easier to work with—perfect for DIYers.
Tools and Materials to Expect
Mike doesn’t list every tool in detail, but you’ll need 1/2-inch birch plywood sheets, a table saw, miter gauge, nail gun, wood glue, and safety gear. A digital angle finder and track saw also help with precision and safety during cutting.
The simplicity of the tool list makes this project accessible for woodworkers without a high-end shop. The key is in the careful prep and clean execution.
Breaking Down the Sheets
To make handling easier and safer, the plywood sheets are first cut into smaller sections. A track saw is used for this initial step, creating panels that are easier to move and rip on the table saw.
By working with smaller pieces from the start, Mike keeps the workflow smooth and minimizes awkward or unsafe cuts on the table saw later in the process.
Cutting Hexagon Tiles from Plywood
The hexagon pattern starts by ripping the plywood into strips about six inches wide. These strips are then cut into angled sections using the miter gauge at precise angles to form a uniform tile shape.
Accuracy is important here, especially when making angled cuts. A stop block helps ensure each tile is the same size, and a digital angle gauge verifies that the saw blade is square when needed.
Sanding for a Seamless Fit
Once all the tiles are cut, each one is sanded using a random orbit sander. Mike uses 120-grit sandpaper to break sharp corners and clean up the edges, which helps the pieces fit together more cleanly.
Sanding also preps the surface for finishing and removes any splinters from the cut edges. Taking the time here pays off in the final installation.
Laying Out the Floor
Installation begins by snapping chalk lines on the subfloor. This reference grid is especially important in rooms that aren’t perfectly square, helping the first row of hexagons stay straight and aligned.
The hexagon tiles are placed starting at the intersection of the chalk lines and secured with a nail gun. A small amount of wood glue on the edges helps lock the tiles together, but they’re not glued to the subfloor—making future repairs easier.
Fitting the Border Pieces
Along the walls, Mike cuts partial hexagons to fill in the remaining space. These pieces are trimmed to fit as needed and tucked under the wall base or molding to hide imperfect cuts.
Since these edge tiles are partially hidden, perfect accuracy isn’t required. The main goal is to complete the field cleanly and prep for trim installation.
Filling and Finishing
After the full layout is in place, wood filler is applied between any visible gaps for a seamless look. A water-based polyurethane finish is then used to protect the floor and enhance the plywood’s natural color.
Mike applies the polyurethane with a large sponge applicator, which helps cover wide areas quickly and evenly. This finishing step locks in the clean, modern look and provides durability for everyday use.
A Bold Flooring Option with Personality
This project is proof that plywood can be a high-end design choice with the right planning and execution. The hexagon layout turns an ordinary material into a custom flooring feature that immediately stands out.
By using basic tools and standard materials, Mike shows that geometric plywood floors are within reach for DIYers willing to take on the layout and cutting process. The end result is a unique, high-impact look with strong visual rhythm.
Please support Mike by visiting his website: https://www.modernbuilds.com/.