Did it 2 years ago and just got the order for this year's trip a couple weeks ago.
They are quite heavy t-shirts, not thin at all. They are poly/cotton blends.
The only thing I would wish for is a little more choice in the picture and font area. Not that what they have isn't nice...it is...We got the Disney Vacation one this time. Love the picture, wish the font wasn't red, would have preferred blue. But that's the breaks and it's a totally minor, completely personal thing with me.
They do run big and they don't shrink. The sizes for adults are more along a Men's size so order for women accordingly. There's a chart in the catalog that helps you decide which size to order.
I looked at doing the shirts myself with iron ons and such and it wasn't going to save me much money, if at all. I looked into other services, but couldn't find places that had nice artwork or I couldn't customize my lines the way I wanted to. Disney's shirts work fine and the price is decent.