Hello all!
Havent heard from me in awhile, as I am busy preparing for our trip Sunday. . . Woohoo!
I have been keeping up with everyones beautiful designs and all the changes taking place. Thanks Baloo and to all else for your hard work and beautiful designs.

I don't think anyone ment to sound critical. You know how addicts get when you mess with their fix!
I just finished my ten family grand gathering shirts today and have made mistakes with my t-designs and transfers all in the name of research!

Yeah right. Anyway. . .heres my DS1 Alexander (AKA Squoose) wearing my design front and back and heres the complete process. It may help someone else.
Each member of our family has a different name badge with their own character. The outlines and font on the badges are all the same.
Kanga-Me

Owl-My BIL Lumpy-My youngest nephew
Roo-Alexander Eeyore-My DS Tigger-My middle nephew
Gopher-Rich, my DH Rabbit-My mom Piglet-My oldest nephew
Pooh-My Stepdad
1. T-shirts are from cheapestees.com. They are Gildan 100% Heavyweight Cotton. I searched extensively on the Internet and this was the only co. I found (inexpensively) that carried matching colored shirts in youth and adult sizes. You can easily find many size shirts at any Tee retailer, but frustratingly they will not carry the same colors for all sizes. Our family shirts span the range between Youth XS which is really too big for toddlers to 2XL. The sizes seemed to run large. I used coupon code W05211 for 10% off before shipping. The shipping was fast and I had a good experience when I had to return a few shirts I accidentally ordered in the wrong color.
2. The design was my idea, but the background map was graciously donated by MidNite. I used PhotoImpact, and I am still learning daily all the wonderful things this program can do. It is fun! The Pooh characters came from a Google Internet image search. All were readily available except Lumpy. I had to extract Lumpy from a web banner image with a lot of cropping and erasing. The majority of the writing is Pooh font and the word World is in the Disney Print font. I downloaded both of these fonts from the internet after a Google search on free fonts. I used the instructions found in the tips sticky.
3. I printed all the back transfers at the same time on best quality and with hp premium paper selected after running a test page on the lowest quality setting to save ink. The adult & youth transfers are almost 8.5x 11. The toddler transfers are about 7.5 x 10. The toddlers also have a smaller badge size. I printed my transfer on Avery paper for dark shirts. It is more expensive than the light shirt transfers, but I find the colors are more intense and white on a design shows up white no matter the shirt color. Also. . .no mirror image printing necessary with Avery dark paper.
4. I double washed the shirts and dried them on high to get them to shrink a little. Not much luck. Oh well. . .eating room! I ironed the shirts inside out to get them smooth as I didnt want to make any of those shiny iron marks on right side of the shirt where the transfers would go. I ironed on all of the badges first after trying on my shirt to get the. . .ahem. . .proper placement so to speak! Then I inserted a heavy plastic cutting board between the shirts to protect the badge while I transferred the main designs on the back. I got this tip from a DISer who posted this just recently. The iron-on process went smoothly for about the first 6 shirts. The last 4 started having problems. I think the cutting board was retaining heat. Anyway, a few of the transfers got stuck to the cutting board. When I pulled them free (no easy task) the transfer had stretched out of shape and created a bubble in the material. I thought I was going to loose it when this happened the first time! But, praise God I let the shirt cool a bit and them reapplied the transfer tissue paper over the transfer and VERY slowly reheated the stretched area and worked it until it shrank back into shape. Whew!

I also noticed that a few of the transfers looked like the colors had blotched. It looked like what happens when you get water droplets on a color printout. Like faded ringlet areas. These turned out to be underdone areas on the transfer. Again, I applied the transfer paper and reheated those areas and the colors corrected themselves beautifully
5. Aside from the fact that the toddler shirts are long enough to be dresses, I think the project turned out well. I learned a lot and am looking forward to going to Disney again so I can try more designs on multiple shirts. I dont know how you ladies do several shirts for one trip. One set of 10 shirts about did me in. Post any questions and I will try to answer before we leave. If not, I plan on posting a picture of the group wearing the shirts, so I can answer when I get back. I am also going to try to figure out how to post the actual design in the gallery in case someone wants it. Help Baloo!?
I hope nobody minds all the info, but I enjoy when folks describe their process as it helps me learn. And sorry the pics are so big. I resized them down in Photobucket, but they still show up large!?

Good luck DDAs!