I made one of Brackins and Harrison Barnes for Barnes' official visit last year, then I proceeded to burn the HB one a week later.
I made mine at Alpha Copies for like $4 and glued in on a piece of cardboard I cut to match the face, but it was in b/w and it looked like crap. Just to get the print of a 2x3 ft face is around $30, which was way over what I was trying to spend as a college student.
Alternative solution: make friends with an engineering student and use some of their print quota to print the images. From a distance I can't imagine that a tiled-together image would look worse than a single-sheet. If you make friends with a CE or a ConE, they may be able to get access to the plotter printer, which could make the image on a single sheet.