There is plenty of room on the new shirts, the picture is deceiving. The one and ONLY case where this might hold true is on a Youth Small Shirt, which the average Scout Shop might sell 2 in a year.
As for the Custom Numerals with Veteran Bars. Plans are still being developed, and National Supply is currently reorganizing the entire Custom Design Department. Have some patience, it's not the end of the world. As always there's going to be a few hiccups when introducing anything new into the market.