Keep in mind that the more colours, the more $$. White shirts are cheaper than black shirts, and black shirts require a layer of white under the other colours, and usually two hits of that white, so they cost more everywhere

You can probably get a white shirt for $1.50, and you can get by hitting most dark colours once. Some of this is moot if we have our own press, but you'll still use up a marginally bit more of ink hitting more colours. And this also depends on what kind of press he's got--a thermal press uses a type of vinyl called Thermoflex, which is actually decently expensive compared to screenprinting, but for only a few shirts, or for lots of shirts with different names on them or something, it's cheaper. however, it's much harder to do multiple colours. As in, it's not designed for it, but if you take several minutes per shirt, you can do it. But, it's easier to do than screenprinting, equiment wise: for heat cure inks, you have to either runthem through an "oven" to cure them, or use an iron or heat gun to cure them. For air dry inks, you have to let them dry, and I have no knowledge of air dry inks. They exist, but I don't know how good they are or how much they cost.
If you all have a design (and if someone designs it, can you split up the different colours and make them all black? You need it black to prepare the screen. And, put "targets" on each seperated colour, so you can line them all up. One target in each corner.) and get money together, I can print shirts at work at cost (as long as I'm not on the clock), which could be as low as $3-5 a shirt (depending on how many colours, and if you want it double sided, etc.)
Stickers are a possibility too, but they are more expensive for short runs: even I have to pay $20 per screen. But, to print a sheet of stuff with a single colour is, maybe $2, and one sheet might have 10 bumper stickers or 20-30 smaller stickers on it. Each colour might add $.50 per sheet (I'm a bit rusty on flatbed printing prices that I as an employee have to pay.) If you print alot of sheets and sell them at $1 a piece, you can easily make money. Clear material, you'd put a layer of white to back the image, then, say, red and blue inks on top of that. My shop prints a buttload of collegiate stuff: If you have anything collegiate on your car, look for a "Fantastic Statics!" or "Fantastic Magnets!" or, I think, "Fantastic Vinyl!" (maybe stickers, I'm not sure what we put on the adhesive stuff).
Tao, your image is 5 colours. White, blue, blue, red, black. If printedon a white shirt, it'll be four colours, but if you cut the blue down to 1 shade of blue (or got someone to make one dark blue, and the light blue would be half tones of the dark blue, in other words, lots of little dots) it'll be a little cheaper. The chimp could probably be done in black with halftones. You need someone with photoshop skills to make thathappen though
