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As Wood stain needs to penetrate the wood itself all coats of Varnish or paint will need to be removed ( I'm assuming its glossed at the moment) Take the door to a door stripping company who will dip the door in Caustic paint stripper chemicals and your door will come out completely bare and...

Before replacing the cill you should really consider if the cill can be taken out easily without damaging the existing framework. (Look for screws or filled in screw holes) If you can then take this to a Wood Joinery/carpentry Co should be able to machine a piece of any design (though this...

There is no set rule for doing this but since you have a cavity wall the inner side will be made from Block and the the outer hopefully from bricks. The trick here is to screw the frame into the blocks and allow about 1 inch to overlap onto the bricks (covering the gap in the middle.