Wish I had seen this earlier. Custom Ink does a fine job, I have used them in the past to have forum shirts made up. Shipping: cheapest route is gonna be the small flat rate boxes. I tried the large envelopes and every combination but it always ended up costing more than a flat rate box. Gotta figure in the cost of the envelopes etc.

If you haven't already submitted your order I can put you in touch with a company that will supply the forum with gear. Give you your own catalog of stuff and when guys want something they simply order it. Takes the burden off of one person.

Here's some of the stuff he's done for me.http://intricate.deco-apparel.com/sh...3&ctype=0&pn=1

If you're interested let me know. Not trying to run your show just sharing my own experiences.