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Hi @Grant-noclue,
Let me tag @NatashaD to share her thoughts as I know she has experience making frames for flyscreens.
Jason
Thanks for the introduction @Jason.
Hi @Grant-noclue,
I used lengths of 25mm fly screen frame, cut using a hacksaw with a fly screen mitre box secured to the workbench with a couple of screws – the mitre boxes cost just a couple of dollars so I bought two as the plastic wears away after a lot of use.
It also helps to work on a big flat area so the frames stay flat. The structural component is aluminium fly screen corner stakes that hold the frames together.
Hope that helps. 
Hi @Grant-noclue,
To add to @NatashaD's excellent advice, here's a simple guide I put together.
Step 1
Measure both the height and width of the interior of your window frame where the screen will fit. If all your window frames are the same size, you can take the measurements from one of the other flyscreens. Make sure the window is square before taking measurements. It would be best to make an allowance of up to 3mm so the frame fits the window. If there is a top track, you also need to allow for the screen to slot up into it and drop back down into the bottom track.
Step 2
The materials you will need:
- Flyscreen frame
- Frame corners
- Flyscreen material
- Flyscreen mitre box
- Spline 5mm x 13m
- Spline roller
- Hacksaw
Step 3
Measure the frame piece along the longest side tip to tip, as this will be the outside of the frame. Ensure the frame is channel side up in the mitre box, and the channel is on the inside of the 45° cut. Use the mitre box to cut a 45° angle. You can screw the mitre box down to some timber to aid accuracy. Proceed to cut the other three sides of the frame.
Step 4
Take your four sides and insert the frame corners into them. They should be a snug fit. Ensure the 45° cuts line up and meet each other. Test fit the frame in the window to see if any slight size adjustments are needed.
Installing the flyscreen is covered thoroughly in Tara's instructions on How to replace a flyscreen.
Please let me know if you need further assistance or have questions.
Mitchell
Welcome to the Bunnings Workshop community @Tkahu. We're pleased to have you join us.
I've moved your post to an existing discussion from last month in which @MitchellMc and @NatashaD assist a member with the same question. I trust you'll find the information above helpful.
Please have a read and let us know if you have any follow-up questions. We're here to help.
Jason
Hello @Tkahu
It's wonderful that you've figured out which product to use. I would have recommended using the Cyclone 910mm x 2m Fibreglass Flyscreen as you've surmised only half the window is actually open.
If you need further assistance, please let me know.
Eric
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