When I moved from BOS to SEA my roommate (who was very into wood working) made me a muddler. It made it through security twice but the third time the geniuses at ORD decided that it was a weapon. Luckily they had one of those kiosks where you can ship yourself stuff so I was able to send it to my destination. They really need to require those kiosks at all TSA stations.

Mind you - I had (and always do have) multiple sharp steel pens in my bag that I'm sure could be used as weapons. But those weren't issues. The small piece of wood, however, was. Maybe I could distract a dog with it?