i don't know of any decent t-shirt places with free shipping that isn't slow as balls also, with those one t-shirt a day sites - there are always ways to find shirts you missed. Woot has The Reckoning and then there are sites like this: http://teetrade.org/ and this site that keeps track of all the one-shirt-a-day sites http://www.teemagnet.com/
+1 for Tee Fury! I buy shirts from there all the time, for myself or for gifts. Whenever I see a shirt that reminds me of someone I get it for them. For $11? Why not?