You wrote:

> The post mentions an expendable version at 15m d but that can't be done on either the current iteration (9m) or v2.0 (12m). The original plan was for 15m but that would require around 100 raptors to get it off the ground!

However, that's not obviously true. This is just a fairing. The fairing can be made wider w/o adding engines or making the booster (or the bottom of starship) wider.

Then you mentioned the stage zero issues, but if an expendable starship with a wider fairing doesn't need to be reused then there's plenty of space right now between starship's nose and the launch tower for a wider fairing, and a crane can be used to stack it instead of the chopsticks if the wider fairing makes using the chopsticks impossible. Even if modifications to stage 0 are needed -or a new one altogether-, if SpaceX ends up building more stage zeros elsewhere (like, say, at Cape Canaveral), they'll have a chance to accommodate larger fairings then.

Ok, I guess only time we'll have to wait and see then, I just don't see it being any time soon.

Certainly. First things first. They have a year's worth of testing ahead of them just to make 100t to LEO reusable launch vehicle a thing. Once they've done that they'll be able to build a new stage zero, work on larger and smaller launch vehicles (smaller because why let others take the by then obsolete Falcon 9's business?) (larger only for large telescopes and such).

Using a crane has turned out to be really problematic; the wind blows the stage all around, hence the arms/Mechazilla.

I don't know what you mean. Are you saying there is not enough room for that next to the stacking tower?

I don't think people are talking about changing Super Heavy.