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the short answer is the space shuttle Columbia on STS-1
The space shuttle Discovery has flown the most times of all the space shuttle orbiters.
the challenger
Neil Armstrong has not flown on the Space Shuttle.
As of the end of February 2010, NASA has flown 130 space shuttle flights, two of them ending in catastrophe.
Neil Armstrong has never flown on a space shuttle mission.
Columbia
2011
Franklin Chang-Diaz
probably the U.S. space shuttle, although the Russian Soyuz has flown alot, too, all the news reporters say differently, the conflict in space partnership between the U.S. and Russia has caused problems...
150lbs. So it can be safely flown by a airplane.
Atlantis was the space shuttle used on STS-38. However, this was the 37th actual flight of the shuttle system. The 38th flight was on mission STS-39, which was flown by the shuttle Discovery.