I started with a chunk of wood from an old pallet.
I drilled holes in the block with the intent of making two different sized cards.
I then used a table saw to cut the block into fins which I could then cut off all at one time.
I also tried the same process on a block that had not yet been drilled to see if I could make the cards and then drill them.
I took the cards to my belt sander and rounded the edges. I used a Dremel to soften the inside of each of the holes. As it turns out, the woman I made them for found that there were still a number of burs on the wood and therefore they didn't work nicely. I'll try sanding them again and perhaps varnishing them to make a better finish.
Sanded cards ready for use? Nope. I recall that when my friend is doing weaving there are numbers on each of the holes.
I used a wood burner to make roman numbers on the cards for use when warping and patterning.
My friend had also mentioned that perhaps leather cards might have been used. I tried my hand at making some of those as well.
My first batch included trying to harden them in hot water but that was a fail! As I recalled the cards my friend used were playing cards. Leather is about as stiff as a playing card so I decided to scrap the leather hardening adventure and just toss these.
I cut some leather squares from scraps in the basement. I then used a small knife to round the edges.
I then used a wood burner to mark the holes as I did on the oak cards.
For the heck of it I thought I'd give the triangle cards a go.
Well, how did the experiment with the triangle cards go? It was not good. Not good at all! That is all I shall say on that matter. Card weaving... YUCK!