Matt:
Nice job of gathering the information thus far…and for taking, “The Bull by the Horns” on this project.
I agree, the best way to handle the next step, would be for you to get all your figures together and make a short presentation at the membership meeting scheduled for December 4t.h.
At that time, you'll also be able to answer any questions regarding the artwork, embroidery and T-shirt idea. We'll also be able to poll the group as to how we should proceed with ordering.
The first quote with the embroidery directly on the hat looks good to me, and an initial order of 48 hats sounds reasonable. A 156 initial hat order (even though it is an exact duplication of the original) may be a bit aggressive. These are the types of things we will need to discuss at the meeting.
I think the more complete your information, the better. Bringing an actual T-shirt to the meeting may be a good idea.
Again, thank you for your efforts, let me know if I may be of further assistance.
P.S. As to one of the previous posting by Dan Wiese regarding hats, mugs and other items that might be available in the "Chapter 582 Store", I have no idea where these items may be, I haven't seen any of it in the hangar. Perhaps someone that reads this may be able to give us some additional information on these items.