Short term, sounds like CafePress is the answer. Maybe after Christmas we can start getting some quotes from other companies and see if we can get anyone who will dropship without making us buy or commit to too many things up front.
I am not interested in personal gain from this venture although help with the costs of running the forum on a private server is always appreciated..
CafePress is a little higher than most but from what I have seen the quality is pretty good, there is no minimum order quantity and they drop ship.
Given the mob who seems to want my head if I don't get SMF apparrel soon, I will get busy on that and should have the stuff ready to order in a couple of days.