Design is all up to you really, Doc. I don't think anyone would object to just replacing name and numbers on the Sulaco patch (well, maybe lawyers, for copyright reasons and all, of course...), but unless people look close, they won't tell the difference and just assume it's the original Sulaco patch. Bit of a waste of effort...
If you have any talent, or know someone who does, design something yourself. It's a lot more fun, and more satisfying.
Here's what I cam up with:
I came up with the general design myself, but I cannot draw a circle to save my life, and I'm even more useless with PC tools. Fortunately, my roomate at the time is a graphic designer, so he could help me out with that. From my starting scribbles and sketches, he came up with that.
After that I inquired here, and Dom directed me to Stadri Emblems (
http://www.stadriemblems.com/). I had a run of 12 made, which is a bit pricey when you're the only one in your squad (sold a couple since, though), but hey. No biggie.

And if there are several of you, the price is much more reasonable.
Here's the finished product:
Now I'm looking for an artist to draw an Aerospace patch insignia. I'm still hoping to rope a friend of mine into coming to D-Con as a pilot for the USS Cyrano wing. She'd look good in a flight suit.
Oh, and as for the numbers... To be honest, I'm a bit confused as to how many regiments there are in the Corps, and how many Battalions in each of those. So I just picked something from the early numbers, which wouldn't risk going over the actual order of battle for the USCM, and that hadn't been used by anyone else I knew of yet. 4th Battalion cause that's my lucky number.
