Is there any way to install the windshield defrost duct after the heater box is in place on a non AC small block? I had to remove the front right fender previously to put a new heater core in and don't want to have to do that again (I have a RS).

 

I think the insides of a 69 are fairly similar to a 68. On my 68', I have not reinstalled mine yet, but when I removed my defrost duct, I pulled it out through the glove box. There is more to remove, but the should be easier than the heater box. You will have to remove the glove box and detach the heater controls and push cables out of the way. The radio may have to come out too along with some wires to move aside. There is more room inside that dash than people think. Take a look and let me know.

 

Turbo86
Thanks for the suggestion - tried it and still no go. I have almost everything out of the dash and it still won't fit. Finally cut and drilled the welds securing the center vertical brace bracket on the instrument panel and removed the bracket. The defrost duct now goes in easily. I will have to weld the bracket back in but will wait until I am sure I have everything else set. There are alignment holes in the bracket so re-positioning it will not be a problem. It sounds like a drastic move but much easier than removing the fender again. With an RS and hidden headlights there are over twenty parts to remove to get the fender off. On top of that there is the risk of damaging the new paint.
Thanks again for your interest and help on this and the other posts you have responded to.
JeffB