3.Are there any clubs out there for collectors of sew on patches?

Answer 1

http://www.kfnut.com/forsale/patches.html

Check out this guy! It's not a club, but you two could start one together!

The easiest way to start a club is either at groups.yahoo.com or you could start a myspace.com page and start a group there.

Finding other people that are into collecting them... now that's the hard part. Good luck!