Shape one end of the wood with the whittling knife to form a curved notch about 1 inch across and 2 inches deep. Round the other end of the maple or ash wood to form a gradually curving point, about 2 inches long.
Draw a half-circle across the wood about 1 inch from the rounded end with the open side of the half-circle facing the notched end on the wood.
Draw two lines about 3 inches long from either end of the half-circle line and perpendicular to the side of the wood. This forms a long "U" on the board. Draw a narrow "U" inside the larger "U" to define the pin in the shuttle.
Drill a 1/4 inch hole directly between one end of the large "U" and the closest end of the small "U" on the board. Repeat this step on the other side of the wood.
Place the notched end of the wood in the vise. Insert a coping saw blade through one of the drill holes in the wood. Fasten the blade to the coping saw. Saw along the line that defines the large"U" on the wood, then along the line that defines the inner "U". Remove the scrap wood. There should now be a hole in the shape of a "U" in the wood with a wooden pin in the center.
Shape the edges of the wood with the 100-grit sandpaper, including the point, sides, notch, pin and shuttle hole to round them off completely. Sand the pin in the center until it is perfectly round and smooth with a rounded tip. Finish the edges with the 200-grit sandpaper to complete the shuttle.