Yeah, kind of a key bit of missing information. ;)
/u/sillytbone, is your dog chewing due to separation anxiety? You may want to consider getting to the root of the problem in addition to buying a stronger crate.
As for the crate, FWIW, I was once recommended an airline travel crate for escape artist / chewer dogs, like this one:
I just got the same kennel for flying my dog from amazon. On amazon they also have bigger kennels: http://www.amazon.com/Petmate-Kennel-Pets-30-Pound-Light/dp/B00AAPGA2W/ref=sr_1_6?s=pet-supplies&ie=UTF8&qid=1429105727&sr=1-6&keywords=airline+approved+pet+carrier
You also need to make sure that the screws are made out of metal in addition to the water and food bowl that needs to be placed in the kennel. Anyways it is good to call the airline again
Also if you have to transit and change the airline , you should make sure that your kennel satisfies both airline requirements.
You have little risk of screwing up the paperwork as it will be handled by a certified vet and the USDA. You just have to get the timing right. IAG cargo will only book your pets on a flight within 14 days, and they need to get clearance from Heathrow Animal Reception Center that they have a spot first as well.
What I did was book my flight with British Airways, and then email (this is their only form of communincation, they don't do phone calls for whatever strange reason) IAG Cargo and tell them I need my cats on that same flight as me (include flight number and date of course), so to email me back when they can begin the booking process.
So, the next step is that IAG get back to you and ask for some info to get a spot booked at HARC (Heathrow Animcal Reception Center), and once that is confirmed they will get your pet on your flight.
For 2 cats it was $1512, so I imagine it would be $756 for one cat. You also have to make sure you have the correct kennel size and accomodations. You can find all that on IAG's site. The minimum size is 28"x21"x22" this is the one I used because it is up to regulation with size and has all four sides with ventilation, and also comes with the "live animal" stickers, and you also have to have water and food containers I used these. There are also people who recommend using metal nuts instead of plastic that comes with the kennels, so I just went to the hardware store and got some just in case. Also you will need to get pet pads in case they wee, which they likely will.
IAG gives you the all the regulations you need to adhere too as I stated above, but as well as forms to fill out when you hand the cat over to them.
As for the entry requirements, you need to get the form from the gov.uk site concerning bringing pets into the country (my vet said it is all done online now, but I would print it out just in case). And then find a certified vet in your area. It cost me $250 per cat for the certification, but keep in mind they also need to have up to date rabies vaccination and an up to date microchip (15 digits, I believe), so thats an appointment to make before you book their flight. I had to update both of my cat's chips for it to comply, as well as their rabies vaccs. And also ask the vet for an official letter simply stating they are in good health to fly.
The main thing is that the certification form from your certified vet needs to be done WITHIN 10 DAYS OF THE ARRIVAL of your cat. So, the vet does the form, sends it (electronically or by mail) to the USDA, who then stamp and sign it and overnight it to you. So, that is another expense you need to pay for, but it shouldnt be more than like $25.
Yikes, seems like a lot! I know. But I handled it ok and I know you will too.
I just recommend getting the cat the rabies and microchip situation done, and then book your flight. Then email IAG cargo and tell them your flight date and number and that you need your cat on the same flight (this is essential, otherwise it will cost you a lot more). They will book a spot for you at HARC, and then once that is confirmed, book your cat on your flight.
I don't know where you are flying from, but I flew from JFK. They don't fly from all airports, so you need to check that as well.
I hope this helps. It was very stressful for me, but it got done and worked out just fine. Let me know if you have any other questions!
I worked for a company that moved pets worldwide for over two years. All the advice about taking the cat in cabin, while they mean well, its impossible. The UK has strict requirements that does not allow any pets to arrive in cabin. E.g. the cat will have to fly in the cargo hold.
Against common misconception, it's actually safer for pets to travel in the hold. It's a pet cargo area that is temperature controlled, oxygenated, and pressurized (exact same conditions as above). The biggest reason it's actually safer is that the cat will have a much bigger carrier, have space to move around, relax, etc and will have access to water bowls during the flight (which is not the case when traveling in cabin). Since you're not traveling over the summer time or winter, temperatures shouldn't be a big concern. There is more risk traveling during hit/cold months, but fall should be a perfect and safe time for animals to travel.
I'm not here for people to disagree or berate me, I'm just giving the facts and am trying to help the OP so please keep opinions away!
The UK doesn't accept 3 year rabies boosters, so the most recent rabies will need to be less than a year old and the microchip must have been implanted BEFORE the most recent rabies (with documented proof).
If your partner wants to travel the first leg in cabin with the cat, you'll need to purchase two separate carriers (in cabin and a hard shelled much bigger carrier for the pet cargo hold). They'll need to depart the terminal and then check their pet back in at the second leg if you want to go this route. However, major airlines are capable of handling pet layovers and the cat should do just fine in cargo for both legs. Layover times are greater for pets because airlines need to ensure they have time to take the pet off the first flight, organize which pet is going where, then get them onto their next flight, so talk with the cargo facility (not AF customer service) about the minimum layover time.
Have your partner call vets in their area now and ask if they are USDA accredited (since the cat will need international documentations approved by the USDA). They should see if the USDA is accepting in person appointments in your area after the vet appointment. If not you'll need to mail it and have it mailed back (I recommend mailing a pre-stamped overnight return envelope INSIDE the envelope to the USDA that is already pre-addressed to your partners house) to expedite if you can't do this in person. The cat needs to arrive within 'x' amount of days of the accreditation (I forget the number of days off the top of my head, but I believe it's 7 or 10 days).
Let her know customs for pets takes wayyyy longer than human customs. Remind her no news is good news and that means that the kitty is just patiently waiting their turn to have their documentation looked over. While waiting the cat will be in a private kennel, outside the carrier, with access to a litter box.
Here's the carrier I would recommend. Petmate Sky Kennel Pet Carrier https://smile.amazon.com/dp/B00AAPGA2W/ref=cm_sw_r_apan_glt_fabc_T07M73FBAJH0G8FTXVG5
Get light crate bedding (can't be thicker than an inch) that's the same length as the carrier and TWO water bowls (10 oz should be fine). Airlines only fill them 2/3 full so water doesn't slosh during take off to keep pets dry. If the kitty soils itself (while rare it does happen) the UK will throw the bedding away most likely, so don't break the bank.
DM me if you have any other questions. The APHIS website is wonderful as well.
Sounds like a fairly bad case for sure, and it seems like you tried a lot of things already and really put a lot of time and effort and money into this, but one thing to consider is rather than dealing with the anxiety, try to deal with what triggers the anxiety.
Essentially, she's perfectly fine in the crate because she knows you're not leaving. But the minute shoes/keys/jackets go on, now she knows you're leaving and the anxiety is triggered. One trainer I worked with said we need to essentially mess with the dog by picking up our keys and jingling them randomly, put our shoes on then don't leave, go in and out of the door randomly, etc. This way, the triggers are no longer associated with you leaving. I've done some of this myself, but what's really seemed to help with our dog is working on holding commands (not just doing the command, but actually holding it until released).
For example, the dog needs to go into a down and isn't allowed to leave the down until you release it with your release word (usually "break"). Then you work up into longer intervals, start with 1 minute, then 3, then 10, and so on. Incorporate it into play time. Throw a toy or treat and make her stay down until you release her. It'll take time to build this skill, but eventually you can then work on transitioning the skill into the crate.
In theory, eventually you can crate your dog, ask her to go into a down, then walk out of the room for a bit. Come back, reward the down, then walk away for a bit and increase the intervals. Eventually she should realize when she goes into the crate and is asked to lay down, it's a command she needs to hold. When she starts panicking, remind her to lay down. Eventually, she should pickup on the fact that it's a good idea to lay down in the crate, which already puts her into a better state of mind (vs panting/pacing/etc).
It takes a lot of time and patience and it may never truly be "cured", but using combinations of the above has taken our dog from literally destroying and collapsing crates and splitting nails and damaging teeth to mostly being able to go into the crate and do his best at laying down and relaxing.
The screaming and whining still happens, especially when we first leave, but for a shorter period of time now. The thrashing and digging while trying to escape has turned into compulsively licking the door (so we're always greeted with a wet smelly dog when we get home haha), but it is possible to improve.
One other piece of advice is to get a crate without bars, like an airline crate. This one worked wonders for ours.