ps We are still hoping for PuTTY tshirts.. ;)

If you're serious about that, then I'm afraid I have to confess that I have no idea how you'd go about getting a T-shirt printed with a colour image on it. Last time I looked into this with my local T-shirt shop, the options were screen printing (limited to one colour), or the nasty laser-printing method which (a) can only make light shirts darker and not vice versa, and (b) seems to give grotty-looking and inadequately durable results.

Talking T's can do multiple-colour screenprinted shirts for an incremental cost per layer, up to about three or four IIRC. Full-colour I think has to be the laser process.

Hm. Well, the PuTTY icon (which was what sunflowerinrain and I agreed ought to go on a hypothetical PuTTY T-shirt) technically ought to include three different shades of grey/white, two shades of blue, and yellow (plus a black border if the shirt itself isn't black). I suppose one could cut that down to just white, blue and yellow by halftoning, but halftoning would probably cause its own difficulties when it comes to screen-printing.

It's annoying. bjh21 has a dark-coloured T-shirt with what looks like a genuinely full-colour image on the front (gradually varying shades, the whole works), so it's clearly possible to make the things, but I have no idea how.

They can also do transfers, as used for the Debian "Grolsch" T-shirt. Those are somewhat less durable though.

Consider Cafe Press. No worries then about print-run expenses.