Whats the smallest vex ratchet i can make rn, i dont have parts on me to test and cad isnt the easiest thing to use to see if it’ll work or not
I’m guessing that a 12t pinion with screws as pawl can make a pretty small rstchet
A good resource on this is by antichamber which you can find Here
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This one I used on a puncher isn’t quite as small, but it’s much quieter

Is it possible to utilize lexan to create a custom ratchet that is much smaller than one created from vex parts?
yes, you can do whatever you want with lexan as long as it follows the rules
Yes
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Antichamber’s designed (mentioned a few posts above) utilizes polycarbonate to make a very low profile ratchet.
This post by team 7842f under the angling hood tab section has lexan cut part that may be good for your purpose but I have not tested it’s volatility.

