It isn't too hard to find someone willing to sell large amounts of BTC at around the MtGox market price with no fee. You can try #bitcoin-otc or the Bitcoin Forum's "Currency exchange" section. Wire transfers and Western Union are the most commonly-accepted transfer methods for large amounts.
It's also very easy to buy MtGox USD coupons. A lot of sellers will trade 1 MtGox USD for 1 transferred USD -- no fee at all (besides the transfer fee).