You might want to try www.zazzle.com -- we ordered from them about a month ago and were able to pick everything (front image, wording, font, t-shirt color, etc.) -- they have a ton of designs to choose from and were pretty reasonable (I think I got them with a 25% off code).
If you are sticking with a disney theme, I think the disney.com shirts are made at zazzle -- but if you want matching shirts that are not disney characters, Zazzle can still set you up.
The custom made shirts thru the Disney site are made at Zazzle. One word of caution...make sure you buy 1 size up than what your child normally wears. I went up 2 sizes for my 10 month old and the shirt shrunk so small it's just barely going to fit him. I did contact the company and they were GREAT about it. They told me to send it back and they'd reprint one (with his name and all) for nothing. Only thing is our trip is in a week and I'm afraid we won't receive it in time. So I'm sticking with the "belly shirt". The other kids shirts are fine, I bought big and they're not too small. Don't forget at Zazzle you can print on the front and the back. Have fun!
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