In order to use the method I'm describing you need 3 tools:
- A hot wire cutting table. I use a proxxon, which is superb but there are other options out there. Don't go cheap on your hot wire table - you use it a lot in terrain making.
- A hex cutting jig - these are not all that hard to make and are required to make precise hexes. How I made my jig can be found this link: Hex Cutting Jig
- A robust straight edge cutting guide - super easy to make and really is the first thing you should add to your hot wire table tool. How I made mine cand be found at this link: Straight Edge Guide
Cutting EPS foam with a hot wire cutter does release toxic gasses which you should NOT breath in. How toxic? I'm no medical expert but have reliable information these fumes are worse than those produced by two day old gas station burritos. Yeah, it's nothing to screw around with. I do my cutting in the garage with the door open and I have a fan behind me blowing the fumes away. Doing so also gives me a wind blow hair look which is a truly glamorous thing to behold. Don't hate me because I'm beautiful.
So without further ado, I present to you :
The Seven Steps to Hex Making Nirvana: