Crawlin' up, flyin' down
Join Date: Jan 2006
Location: Democratic Peoples' Republic of Berkeley
Bikes: 1967 Paramount, 1982-ish Ron Cooper,1986 De Rosa Professional, 1978 Eisentraut "A," 1961 BianchiCompetizione, 1994 Trek 520, 199? Burley Bossa Nova, early-1970s Cinelli Speciale Corsa
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Voler does both partial custom (your words on pre-designed jerseys) and full custom. Their jerseys are some sort of synthetic. I have one of their jerseys, and they're pretty well-made. Google "voler bicycle jersey" and I'm sure you'll find them.
Portland Cyclewear (I know the "Portland" part is correct; I think the "Cyclewear" part is, too, but I'm not certain) also does both partial and full custom, but in wool. I don't have any of their stuff, but have read good things about them here on BF, both in terms of quality and price. Google "portland wool bicycle jersey" and you should get to them quickly.
If I remember correctly, Voler's minimum order for full custom is significantly smaller than is Portland's, but the websites should clear that up pretty quickly.
Also, there has been an add for somebody or other in the electronic version of VeloNews advertising custom jerseys - I have no idea who or what their product is like, but that's another possible source.
Cool idea. I hope it works out for you.