You are a good man…

It takes a quality tool to do a quality job!
Your cart was assembled with quality tools and was attempted to be taken apart by non quality tools! There's a reason technicians use them, it saves the customers money in the long run. Just remember fiberglass and paint have low burn points! Before you go drilling wildly be careful!

Love your description of the POWER TOOL operator. Don’t know why they use power tools to run a tiny screw in! I guess they were in a hurry & wanted to make sure it wouldn’t vibrate out.

Toymeiter has very direct way of putting things. :)

Screws were probably locked in with liquid glue. IMO the hardware should of been countersunk screw with fiber-nut and washer on back. That way can easily be replaced. But with no panel covering makes ugly appearance on inside?

It’s still very tricky being so close to edges of panels.

All, I have actually done this onanother street cart. I have both steel and aluminum inserts if necessary as well as backing plates. So once i get my hands on the door I will see what needs to be done. I like all of the suggestions.

Tinker
 

Tinker is a true gentleman. We need more like him. If all else fails, take it to Villages Golf Carts.

You have to love someone who refers to people who are trying to be helpful as "idiots".

Wow. Just when you think you've seen it all.

Are actually two types of screw extractors. One is square and you drill a hole and tap it in and turn out the screw with a wrench. The other you drill a hole and it is reverse threaded so it tightens as you twist it with a wrench to remove the screw. Frankly either works better with larger screws than these seem to be. A broke screw, typically the screw breaks jut below the head. I would tap a starting spot and drill out the screw. Getting out the screw is only part of the problem. Finding a matching hinge,
may be bigger problem.

I too am stubborn. I think the poster said golden oldies. They made it perhaps let them fix it. This seems like on of those simple projects that turns into a disaster. Damaged paint-cracked fiberglass etc.

Another vote for David "Tinker". Easy fix for him...
:bigbow::welcome::bigbow:

I do not do marriage counseling. Night before I got married my dad long gone now passed on family wisdom. I think it came from my great great, perhaps one more great grandfather. You will never understand your wife. If, you do, first of all it will quickly change so not only are you wrong it is your fault..

You could be right!

Villagetinker you are the best
 

How can I thank you enough. So kind of you to give up your morning to help us with our golf cart doors. We need more David's in the world. THANK YOU, THANK YOU, THANK YOU!!!!!

To all that offered advice on this repair. It was interesting, 3 screws had the phillips head stripped. 2 screws had the phillips head actually break off the screw body. 2 screws were in so tight I had to cut the hinges off to get a grip on the screws to remove. One actually came out easily. Eventually I was able to remove all but the 2 screws that broke. These had to be drilled out. All of these screws were stainless steel, which required Cobalt bits, oil and lots of time drill out. In the end I was able to get all the screws out (8), the owner provided new stainless steel screws and i was able to install the new hinges, all in all a productive morning.