I, too, have looked at the interior door hand screws of the IV and ES and thought it was a dumb design. Here's what I did to minimize the chance of failure: First, recognize that a flat-head screw is the wrong thing to use in this application. The screw is loaded in pure shear and the wedging effect of the screw head tends to create a bending load. But it's too late to go to a round-head screw. Also, the tension in the screw adds unnecessarily to the total stress. Given that, I put Loctite on the threads and then just tightened the screw snug - essentially no torque. All screw torque can do in this case is keep the screw from loosening, and the Loctite will do that without adding stress. And I added an interior release to the (enlarged)
baggage door just in case. Mine hasn't yet broken, but now that I've said it out loud, it will break the next time I try to get out!
Gary Casey