Have you compared costs with somewhere like Spreadshirt? They seem to do a good line in T-shirts, using American Apparel Ts that aren't *too* expensive, and they've other knick-knacks you can ornament. Plus they definitely don't demand you take a royalty. (Disclosure: the NY Doctor Who group uses them for their 'brand' merch.)
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Have you compared costs with somewhere like Spreadshirt? They seem to do a good line in T-shirts, using American Apparel Ts that aren't *too* expensive, and they've other knick-knacks you can ornament. Plus they definitely don't demand you take a royalty.
(Disclosure: the NY Doctor Who group uses them for their 'brand' merch.)