Dang it! I broke a screw!
Actually, this happen last year but I thought I would share how I resolved the issue.
I was building cabinets using hard maple. Even though I had predrilled a pilot hole in the door frame, the screw broke when I was screwing it in. Either the pilot hole was too small or the screw was too big. The idea of having to make a new door made me sick at my stomach.
After taking a break and thinking about my dilemma, I devised a plan to repair the broken screw. Note that this may or may not work in other situations, but it worked perfectly for me in this instance. Note: The screw broke flush with the wood. There wasn't anything that I could grip with pliers. Step 1 - Remove the broken part of the screw
After removing the other screw and the hinge, I used a plug cutter to cut around the area containing the broken screw threads. Using a hand held drill, that was actually easy to do. And wouldn't you know it, I broke a second one while removing the hinges!
Now that I think about it, maybe the cordless drill had too much torque and simply snapped it off. Step 2 - Plug the hole
Using the next larger size plug cutter, I cut a few plugs from the same wood the doors were built from (hard maple). After that, it was a simple matter of gluing the plug into the hole(s).
Step 3 - Finish the repair
Once the glue was dry, I taped off the surrounding area and sanded the plug flush with the frame.
Step 4 - Reinstall door hinge
I used a slightly larger pilot drill bit and hand screwed the screws into the hinge. Not surprisingly, all went well.
There is no evidence of any repair because the hinge covers the repaired area.
Hope you find this info useful. File it for future reference. You may need it some day.