OK, I should get the shirts tomorrow and here's the deal - if I can wad one up into the same box as we used for the hats, and keep under a pound, then we may just do it that way and go Priority Mail. If the package winds up being over one pound then I'll have to think of something else as Priority Mail between 1 and 2 pounds will be $7.20. If it turns out to be maybe just an ounce or so over then maybe a big Tyvek envelope would be cost effective if it brought the weight back to under a pound, we shall see...
With the numbers who pre-committed it looks like the final shirt price will be $12. I don't think that's out of line for a good quality embroidered T-shirt. Now that the logo setup has been done anything else produced with this logo will not have a logo set-up fee associated so I could see sweatshirts, polo shirts, jackets, etc possibly in the future...