What would people say to the idea of 4-ch merch? I've been wearing the organic fitted tee version of this one for a couple years by now, but why not open an official shop on some printing site like Zazzle, Spreadshirt and/or Cafepress to help pay for hosting bills?
DQN-kun and pretty much all our AA heritage comes from 2ch anyway, which is posted there without any copyright and is not owned by 2ch. So you're free to do whatever you want with it.
I would definitely buy some printed merchandise. And although the simplicity of AA makes producing your own designs pretty simple (I drew a large ｷﾀ━━(ﾟ∀ﾟ)━━ !! in marker on a white shirt), having them somewhat professionally done would be cool.
I'm not so sure about 2ch being fine with it in that case. They were quite angry when Avex started selling Giko/Monar derivative AA character merch in 2005 (cf. http://ja.wikipedia.org/wiki/%E3%81%AE%E3%81%BE%E3%83%8D%E3%82%B3%E5%95%8F%E9%A1%8C "Nomaneko Problem").