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well alot of the questions you are asking im checking them off my list when they do get answered,so ask away..
Detroit Muscle has the A/C kit also...contact them & I'm sure they will exchange, the a/c kit will be a few more dollars, http://www.detroitmuscletechnologies.com/pdfs/DMT%20CATALOG%2070-74%20E%20BODY.pdfEXX7074HB10A/C heater box foam restorationKit70-74 Challenger, BarracudaINCLUDES INSULATIONEXX7074HB31$65.00
lol i take it your doing a simillar project?