How about, for paid members, the ability to get your own http://username.lj.com instead of www.lj.com on the shirt?
A) The shirt design is probably done/submitted/ready-to-roll (maybe next time)
B) Individual printings are more expensive than bulk (see below)
C) Do we really want to push the individual over the community? (No)
If we did a buy-an-account AND a shirt promo, would it be more cost-effective? Probably not. But it SOUNDED like a neat idea. And that's what's really, truly important. How things sound.
Anyway, everybody have a nice weekend, and keep the money suggestions flowin'.