The 2" bolts barely went through so they are too short but I found some #6-32 in 3" at the local hardware store & got 6 of them (2 extras in case of stripping, breaking, or loss). Good thing because I misplaced one of them. The shorter bolts did come with nuts though.
I tested to make sure the bolts went all the way through the holes without the pet door pieces. Then I tried to fit them together but they wouldn't line up. Redrilled, enlarged the holes, etc & tried again. The bolts will slide right in to the inner pet door half from the other side but I have to use a screwdriver to get them to go through the outer half (and I start from the outer half). I was having a hell of a time with it. I had to flip the door over again & I've decided to nix the idea of painting the door and then putting the pet door on because that will be a royal pain & I will probably scratch the paint while trying. So, once I get both halves on and secured they are staying there. I'm going to caulk around the pet door & then use painter's tape to cover the pet door & paint the door. I'm hoping that some primer might help hide some of the scrapes on the door from flipping it over & moving it around. The door came primed already but I want to use primer over where it got scraped off.
I did end up using some of the white duct tape I got to seal up some corners and hold the steel tighter to the foam. When I was drilling out the holes in the square corners the foam started eroding a bit too much & I could see the bolts but there is still steel holding them in place. I reinforced the corners with tape. When I get the inner frame in place permanently, I'm going to put tape inside & wrap it around the steel edge on the other side to seal it up & hold it tight before putting the outer half on. It's going to be tricky to make sure everything lines up.
Right now I have it set in place with the bolts going through just the holes (without the other half) and through the inner ring to make sure it lines up enough. When I put the two halves together without the door in between the holes line up. The bolts slide through the holes in the door relatively easily now so I'm thinking of screwing them in to the outer frame so they stick out far enough to go through the holes in the door & stick out the other side enough that I can make sure they line up with the other half, then tape the bejeezus out of the inner frame to lock it in place, and finish screwing in the bolts & securing them with the nuts. I can trim off any excess that sticks out too far from the door frame & I'll hit them with white paint. The nuts are too large to fit inside the holes meant to hide the screws.
It was cold and rainy today & it was dark, cold, and rainy when I left the workshop. I have one more picture I didn't upload (my computer isn't reading my phone so I have to send it to myself via FB messenger & download). I did upload a few more photos though. I have the urge to go back down there to work on it now but not in this rain & with it being so dark. LOL.
This is the threshold that came with the door & frame (floor needs to be re-sealed):
This is the frame from afar with the door on the work table. The ladder behind goes up to the little loft area over an insulated room (there is a tropical poster on the door to the room):
Outer pet door piece in place:
I traced around the pet door with pencil in the hopes it would help me line it up again when I go to put it back on. There were only 2 lights on in the workshop but they are LEDs and they are *very* bright so they lit up the whole room. The old fluorescent lights sucked. I had the paintbrush on the door to sweep away debris after drilling & cutting. I had to crack out the dremel to smooth out the steel where the drill bit poked out and pushed it out a bit & then I used a hammer to flatten things even more.