as to soyuz being too small first what job and how many people do you
need to launch at one time?

I think the upgraded apollo size capsule holding 5 was enough, the CEV
7 was unnecessary, it was nasas attempt to need a new launch system,
and pay off existing contractors

the apool upgrade could hold 7 in a emergency return from orbit
situation.

more people thanks to the shrinkage of electronics in all these years

on dismantling the ET production hardware what plans were in place if
a ET were somehow damaged or lost in transit?

was there one extra one being held in reserve?