Brad, The colors just have to be close as you can see by comparing the original artwork here to the actual patch example in the first post.
As far as size, I guess we would want a quote on actual size and perhaps also a quote for one small enough to fit on a typical ballcap...
I would say quotes for orders of magnitude starting with 50 and incrementing by 50 till you reach 200...
Here is the artwork in both sizes...
Thanks again for researching this...