with cafepress.com anything is possible. creating the merchandise is free and you select how much you want to sell it for. It's not just t-shirts either. they have coffee mugs, button, bumpers stickers, mouse pads, etc.
Gentlemen, your ideas are very good and I think that this could be a possibility. Chris, perhaps you could check some ballpark pricing on what it would cost to make a few types of items, such as T-shirts and coffee (tea?) mugs: "Opinion like tea leaf in water - both need time for brewing." My hope would be to sell anything at non-profit prices, and, I would not expect that we would need to produce very large quantities of merchandise.
If you look at the website of Cafepress.com, you will see what I am talking about. Basically you upload a picture or saying and attach it to an item (t-shirt, mug, clock, etc.) It costs nothing but time to do it. Then you set the price and the items are not made until someone orders it online. There is no inventory, no overhead, etc. etc.
Everything is handled through the website. Further questions, e-mail me or check out my personal store located at Mentzer's Tower of Merchandise
I found a site that has a shirt with a picture of Sidney Toler on the front and the caption "What Would Charlie Chan Do?" on Ebay. There were two. I bought one. :)