Now both halfs are ready. Front half has the core attached with 4 screws - sealed with caulk. Temperature door is lied into it's groove. Rear half needs also some caulk.

To put the halfes together was the most difficult step. Slide in the air-vent door in its hole and keep everything on its place... needs some ingeniousness and patience.

So here it is - back in live. To attach the thick D-shaped gasket on the top it takes some weatherstripe glue. And now is a good time to test the fan and the resistor - if it runs in 2 speeds. On this pic I forgot to attach the ground wire of the fan to the metal backside plate...but I remembered later.

I didn't had this hook in the car - it was missing. I found in the shop manual, how it works and bent a stud to do the job.

Welcome back. Since the blower motor is grounded via the metal plate on the backside of the unit, it's important to make sure that at least one of the three nuts that fix it to the firewall allows electrical contact (just in case you painted the firewall in the meantime - as I did).

When testing with the upper ducts in place I found that "the gap" causes quite some air to be blown under the dash...

I assume that the upper ducts may have warped a little (or were assembled without care 40 years ago). Just in front this part is to close to the heaterbox, on both sides it's okay and no air goes the wrong way.

Since I don't like the idea to heat the inside of the dash, I fixed a stripe of alu sheetmetal.

Wow it looks real nice, great work.

That gap between the box and defrosters is supposed to be there. It mixes air for the defrosters, Pretty sure.

Can someone help out with this part of my heater box rebuild/resto?
I am missing the hook that is shown in the picture. Unfortunately, I don't have a shop manual to reference, and need to know more specifics on the size, length, and where it attaches up in the cowl vent, etc. Can someone help? Thanks.

This is the actual part (J-Hook) I'm in need of. Thanks.

I might see if I can have these hooks made. Sure it wouldn't be a huge seller but would compliment my product line.

I would have bought it, if it were available!

I can remember that it was quite a pain to get this hook attaching to the cowl. Mine was straight (I didn't know better) but that corner in it will help a lot.

Anyway - my car is still not back on the road

To many cool things to do - including too many other things to do at that car to make it a bit more perfect. Well, the engine runs, it has brakes and exhaust, even a carpet is in. May be adding wheels, including steering wheel and seats would make it more to be nearly finished...

Ouch.

I thought I'd share an update on the heater box J-hook. I purchased an A-body hook on ebay for $14.00 total (see 1st photo). Using the photos and measurements that C O D Y provided, http://www.cuda-challenger.com/cc/index.php?topic=91192.0 , and additional photos of other E-Body J-hooks, I fashioned one from the A-body hook. I think it came out pretty good. I believe the measurements and angles are close enough to be a working E-body heater box J-hook.

*** The last two photos are a couple of reference photos I used.

Thanks for all the help.