Cafepress is a little pricey, have you checked locally?
I've been tossing the idea around for almost a year now on whether or not to start doing this.
The not for profit guy I was going to went out of business a few years ago.
Maybe I need to look into this some more?
When I had the HauntForum shirts made, I used a company called Custom Ink. Their prices are lower if you buy in quantity, and I was able to get free shipping. Not sure if they're still doing the free shipping though, so you may look into that.
Actually TD, what I meant was, producing screen print shirts for home haunters. There just isn't anyone out there doing it for a reasonable price (that I've found).
I was getting my shirts (these were heavy Fruit of the Loom) with 2 colors, front and back for 7.25.