I just made mine and did it the simple and easy way:
1. Buy or find the t-shirts you want to print on.
2. Go to
Walmart, Office Depot, Office Max, etc and pick up some t-shirt transfer paper for your inkjet printer (I"m assuming you have one). They come in two types - for light or dark shirts. it was around $12 for a pack of 6 I think.
3. Do you have Microsoft Word or something similar on your computer? You can use a fancy graphics program, but really all you need is Word. Open a blank page like you were writing a new letter.
4. Go to a clip art site for Disney. There are a bunch, but here are a couple to get you going:
http://clipart.disneysites.com/
http://www.geocities.com/disneyclipart/
When you have the picture you want, click on it to get the bigger version. Then put your mouse over the larger version and right click on it. Select Copy from the menu.
5. Go to your blank page in Word and Paste the picture into your document. You'll see little squares around the picture. If you click and drag on the corner ones, you can resize the picture. If you just click and hold on the picture, you can put it wherever you want on the page.
6. Type in whatever else you want on the shirt (their name, a saying, whatever) just like you would a letter. In order to make that text moveable anywhere on the page, you may need to go to Insert -> Text Box, then type in your name or saying. That way you can move it around like a picture too. You can use any font you want.
7. Once you have it laid out on the page like you want it, print out a test page using NORMAL paper first to see if it's what you want. Once you're happy, it's time to use the t-shirt transfer paper.
8. Follow the directions that came with the paper as to which direction you put it into your printer.
9. Make sure you have your printer set to the highest quality and color.
10. Print out your design.
11. Follow the iron-on instrucitons that came with your paper and iron it to your shirt! (it varies slightly by which type you get).
That's it!
If you don't have Word you can use Works, or any other program you use to write letters. If you get fancy, you can do it up in Microsoft Publisher, but you'll be fine without it
Hope that helps,