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Can they replicate shuttles (or at least most of the parts) ?
That’s why everyone had to always be on replicator rations: Janeway’s coffee addiction and constantly replacing shuttlecraft.
if Janeway could only get coffee back at earth she probably would've violated every directive of Starfleet just to get back home
She did anyway
I think it was just to give Neelix (and the Doctor) something to do.
the delta flyer was built from the ground up afaik so I guess they can
They made it out of the infinite shuttles.
And it was designed to be a long range exploration vessel so it makes sense.
But it also has a new untested holodoc and computer and warp nacelle config.
So new long range outside space station repair range and new untested config. Great plan overall.
They had a real doctor, he gets killed in the pilot.
In Prodigy, the USS Protostar has a vehicle replicator that it uses to print shuttles on demand. The Intrepid class was fairly resilient and self-contained, so it's a fair assumption it would have something similar, but we never see one on screen or even directly mentioned.
Iirc they made mention of an "industrial" replicator at least once
it's entirely possible; I personally don't remember and I can't find a hard reference in Memory Alpha on any relevant pages (industrial replicator, vehicle replicator, Intrepid class, uss voyager). Most of the memory alpha references are in DS9.
Industrial replicators are only ever mentioned on DS9, at least according to chakoteya.net.
Janeway can summon them out of thin air (I don't know it never said anything about it)
she's chummy with Q so probably gets him to do it in return for babysitting his kid
Janeway doesn't wanna deal with that bozo, she probably just time-travels to get blackmail on Q to keep time-traveling in a big loop
That's how they built the Delta flyer.