I think it is the spring load on the hinge that is the problem. There is so much power in the spring that it warps the door and brakes the tabs where the screws go. I tried to repair the door but ended up buying a new. I had the hinge apart and sent it for replating. When I put the hinge together I didn't spring load it.
Now I have to hold the door when I open it, but when it is closed it looks OK.
I have read about similar problems with AAR hoods. Fiberglass hood and too much power in the springs. Some guys have reinforced the fiberglass with steel bars.
Maybe you can build an inner structure in the console door from metal that can take the power from the spring?