[SML] Skinny screws?

[Joe]

Locally lumber has jumped in price, so we are looking at trying to use less lumber.  We typically use 2x3 for most of what we build, not because we need the strength of a 2x3, but because it can take a lot of abuse and not split on us.  Personally, I prefer to go with lighter weight builds if I can.  It is just easier to handle. But, 2x2 is a little more prone to splitting, and 1x2 is very much more likely.  I know drilling a pilot hole helps, but that takes an extra step.
We typically use standard drywall screws. I see there are fine thread drywall screws, but when I look up the O.D. and Root diameters, they are the same as coarse thread drywall #6 screws.
Today, I tried to use 1x2 as much as possible for a gas range set piece from the 40's.  I was careful to drill pilot holes anytime I went into the 3/4" side of the 1x2. And I didn't have any problems.
We have also  shifted to using Hardboard instead of Luan. At $9.19 for a 4x8, it is a lot cheaper. But, I find it frustrating that it is only 48 3/4" wide. I am sure that is for a reason in some applications. But, I prefer a true 4'x8' sheet.
Any other ideas?
-Joe
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