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I ship one T with First Class Mail, in bags that I bought from U-Line. (cheap in bulk). More than one T I ship Priority Mail - you can fit 3 t-shirts in a Flat Rate Priority Mail envelope - $3.85. Overseas in Global Priority Mail Flat Rate envelopes - about $7 anywhere. If you use Paypal to ship, you get Delivery Confirmation for 13c. Or you can ship via USPS website, I think you get some off then too.
 

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I don't think the cardboard envelopes are bad, Twinge - I've shipped 3 (heavy) t-shirts in a Global Priority Flat rate envelope to Germany, got there with no problems. What is the worst that could happen - a couple of wrinkles? Just make sure you tape the opening securely so that it doesn't pop open.
 
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