Is there a minimum length? I need it for my carry-on (over the seat), and want to make sure it can be adjusted down small enough.

As an owner of two of these straps, I can tell you the shortest it will adjust to is 42 inches. Hoping this helps!

Can u make the strap larger when locked?

Yes you can. Rather difficult to make it smaller/really tight when around suitcase, though. Making it larger is easy. I travel lot & this strap has never failed & I know have had luggage spot-checked by TSA with this combo locked around suitcase.

What is the buckle size and what do the buckle ends look like when the buckle is open?

You tube how to reset combination to see size and what it looks like open.

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