Cool. How can I make one of these?
I think if you change your restore sequence to creating a new empty Backup2disk folder, then dragging the restored BKF files into it, and performing an inventory it will eliminate the Physical volume library not found error.
Rename your existing \Catalog folder to \Catalog_old; create a new \Catalog folder.. Stop/start services.
Goto the media tab and verify the restored BKF files do not exist in the all media list. If they do, move them to the retired media set and then delete them.
Now your system is fresh of any incomplete cataloging operations.
Perform another B2D folder inventory. sort the BKF files by date within the devices tab.. Each backup set should follow a continuous timeline. Right-mouse click the oldest file only and select catalog. It should work. If the job fails, try the next oldest file in a continuous timeline (media set).