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@samawry
re: 1. buy cheap bulk ready-made t-shirts etc...
we all agree, sewing lugs onto panels increases cost. Just thought i'd mention 'foiling'. Transfer printing metallic stuff onto garments. You usually see mirror, gold, or black - and actually i think its super cool to foil across seams so it kind of cracks and peels (not sure what that might suggest about quality frame building... but its a really nice surface treatment)