Sorry to post if obvious answers, or only Excalibur lot can answer (have emailed and pm'd Mark, but no response yet).
Any scripter who knows what he's doing should be able to answer these. This is more of a scripting question.
Are the crew member sizes fixed? It seems:
Saffi & Felix - Large
Kiska - Medium
Brex & Miguel - Small
No, these are defined in the character configuration scripts. Each bridge (for a very long time I didn't download a bridge mod) used to have its own configuration scripts for each character.
Char sizs is i.e. defined by something like this
pChar.SetSize(App.CharacterClass.SMALL)
pChar.SetSize(App.CharacterClass.MEDIUM)
pChar.SetSize(App.CharacterClass.LARGE)
and you can also set the characters scale using
pChar.SetScale(1.0) # float value
But this changes on some bridges.
As I said each bridge has different config settings, each unique scripts (of course some bridges reuse existing scripts but you can write new ones).
And can anims from one size be applied to another? e.g., can Brex use Felix animations?
Animations are also defined in these scripts, one by one. You also define random animation chance, blink rate etc.
Just trying to give you some kind of prespective.
But remember that 3rd era had a scripter to help them in certain areas (they had Mleo, then later on Lost_Jedi or LJ now).
Oh and BTW if you switch sizes you can then switch from using i.e. you had a character which was small then switched to large you can just swap to use the large animation types then (mind that some animations are considered common).
That should have you covered.