We've inherited a customer who after auditing their site turns out they used to have a site-to-site VPN and another DC at the endpoint (which was the only GC in the forest). THe previous IT company demoted this, cleaned up AD, but never made their now main DC a GC.
We want to replace their current DC (2003) with a 2008R2 box, is it best to make the current DC a GC first then dcpromo the new DC, or does it not matter? Bare in mind the new DC will be made a GC.
I would recommend (and so does Microsoft) that you make all domain controllers global catalogs unless you have a very good reason not to.
You need network access to the RID Master FSMO role holder for the domain before you can promote a writable domain controller. Otherwise, only an RODC could be created, which I'm guessing is not what you want.
But to answer your question more directly, a domain controller does not need a global catalog to be promoted into an existing domain.
Edit: I have verified via lab testing that I was able to promote a new domain controller into an existing domain with the bare minimum of a non-GC domain controller online that was hosting the RID FSMO. The other 4 FSMOs were down and no global catalog was up.
Here's some more info from the fantastic AskDS blog about other reasons you will want a global catalog online, even in a single-domain forest: