Were they breaking off on removal, or on re-install? On install you dont have to tighten them that tight, I use a 1/4" drive ratchet. If you don't want to spend time drilling them out, short self tapping bolts will work just as well.

It shouldn't be nmore than a couple of $100 to paint the door and fender, you should have enough left to get some goodies. It is rather amazing for what little damage was done that the Ins. wanted to total it out. I hate seeing a perfectly good Toy(w/a little help) get parted out.

More than tread lightly. Leave it like you were never there, nor anyone else.
'90 X-cab 4.88's 33 BFG AT's, rr ARB, Headers, Ignition upgrade, cold air induction.
'91 X-cab 5.29's 315's BFG MT's, rr ARB, custom bumper and flatbed