Easy Hexagonal Wood Post From a 2 by 4
by rschoenm in Workshop > Woodworking
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Easy Hexagonal Wood Post From a 2 by 4
![IMG_0281.jpg](/proxy/?url=https://content.instructables.com/FPN/2PKB/IJ7WO978/FPN2PKBIJ7WO978.jpg&filename=IMG_0281.jpg)
Follow these instructions to make a hexagonal post from a 2 by 4.
You need a straight 2 by 4 and a table saw. A planer or jointer will be helpful if you have one.
Prepare a Blank
![hexagon post1b.jpg](/proxy/?url=https://content.instructables.com/FWK/ALZZ/IJ3GMFO8/FWKALZZIJ3GMFO8.jpg&filename=hexagon post1b.jpg)
![IMG_0255.jpg](/proxy/?url=https://content.instructables.com/FRZ/OIQS/IJ7JKWMA/FRZOIQSIJ7JKWMA.jpg&filename=IMG_0255.jpg)
![IMG_0256.jpg](/proxy/?url=https://content.instructables.com/F8Y/Z1WO/IJ7JKWMC/F8YZ1WOIJ7JKWMC.jpg&filename=IMG_0256.jpg)
![IMG_0258.jpg](/proxy/?url=https://content.instructables.com/FTN/4AXE/IJ7JKWMD/FTN4AXEIJ7JKWMD.jpg&filename=IMG_0258.jpg)
Cut a 2 by 4 in half or into fourths. Mill the pieces on a planer or jointer to get all four sides flat and square. A table saw will do if you don't have a planer. Rip and/or plane the pieces to a 2-3/4” by 1-3/16” cross section. Be accurate.
If you want a hole down the length of the hexagonal post cut a dado along the middle of two pieces - on the 2-3/4” wide face.
Glue two pieces together. Use Titebond III or another waterproof glue for outside applications. The resulting piece will have a cross section of 2-3/4” by 2-3/8”; with an optional rectangular/square hole down the middle.
Cut the Hexagon Shape
![hexagon post0b.jpg](/proxy/?url=https://content.instructables.com/F74/YLAV/IJ3GMFNF/F74YLAVIJ3GMFNF.jpg&filename=hexagon post0b.jpg)
![hexagon post2b.jpg](/proxy/?url=https://content.instructables.com/F84/3K6S/IJ3GMFOV/F843K6SIJ3GMFOV.jpg&filename=hexagon post2b.jpg)
![IMG_0262.jpg](/proxy/?url=https://content.instructables.com/FFN/22HZ/IJ7JKWN6/FFN22HZIJ7JKWN6.jpg&filename=IMG_0262.jpg)
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Set your table saw blade at 30 degrees. Set the angle as accurate as you can. A 30-60-90 degree drafting triangle might help.
Set your table saw fence to 2-1/16" inches.
Make four rip-cuts as shown to slice four triangles off the corners. Be sure to put the wider 2-3/4” face down when making the cuts. Use extreme caution when making these cuts as the wood is no longer fully supported on the bottom for cuts 3 and 4. Also, the triangular cut-offs may be thrown off if caught under the blade - stand out of the way!
Finished
![hexagon post3b.jpg](/proxy/?url=https://content.instructables.com/F0H/NY2Y/IJ3GMFPO/F0HNY2YIJ3GMFPO.jpg&filename=hexagon post3b.jpg)
![hexagon post4b.jpg](/proxy/?url=https://content.instructables.com/FHV/ZODT/IJ3GMFQJ/FHVZODTIJ3GMFQJ.jpg&filename=hexagon post4b.jpg)
![IMG_0280.jpg](/proxy/?url=https://content.instructables.com/FGZ/BFYK/IJ7JKWO1/FGZBFYKIJ7JKWO1.jpg&filename=IMG_0280.jpg)
![hexagon post5b.jpg](/proxy/?url=https://content.instructables.com/F4L/3J10/IJ8Z7MYU/F4L3J10IJ8Z7MYU.jpg&filename=hexagon post5b.jpg)
You are done.
The resulting hexagonal cross section will be 2-3/4" in diameter (D) with each side 1-3/8" long. The glue line will be nicely hidden along two of the edges.
Use for a lamp post, table or bench legs, book shelf supports, baluster, candle holder, turning blank, etc. Or slice off hexagons and assemble into .... whatever!
For other diameters D prepare a rectangular blank of D inches by (0.866 x D) inches, and set the fence to (3/4 x D) inches as shown in the last diagram.