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Hi: You could use treated lumber for the door sash. The bits for the stile and rail start
at 1 3/8ths" because that is the standard for exterior doors. Making it some other size
may make the job tougher, since lock sets and other hardware are basically made for the 1 3/8ths thickness. The door could also be mortise and tenon joinery. The screen you want to save could be set into the door with a rabit. Good luck.. Woodnut65
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