Short version: If you're only going to wear the shirts you make yourself, you are probably fine.
As far as US law is concerned, whether or not you made money is irrelevant to whether something is a violation or not. Profit only enters the picture after the verdict, in determining the amount of penalty you might be liable for.
Both Trademark and Copyright law may be involved, the former in regards to the SR logo as an identifying mark, the latter in regards to the artwork inherent to the logo.
Under Trademark Law, whether or not it is a violation depends largely on the '"likelihood of confusion" - how likely it would be for someone to mistake the product marked as "official". If you are not offering the product to others, nor passing it off as official, the likelyhood of a violation being declared is probably pretty small.
For Copyright Law, it's two out of the five possible violations: Reproduction and Distribution. Reproduction is almost never charged by itself, it's usually tacked onto Distribution. This is because by itself, simple duplication might be considered for personal use and thus fall under Fair Use statues. Distribution is passing a copy to someone else without permission.
Derivative Work, Public Display, and Public Performance aren't really applicable here. Well, possibly Public Display, but that'd be kinda iffy.
In any case, Catalyst has an official fan license, doesn't it?
-k
