rar ( with password ) to multiple files ..burn the even numbers on one disc ..the odd numbers on another ..send separately ( different envelopes and couriers )..send the password via email ..
let the recipient reassemble
( tell them copy all files from both discs to the same directory on their machine )
plenty of free apps that can unrar
you can even make the rars into an auto exe..and still send the even and odd numbers seperately ..on receipt ..they copy all to directory and run the exe ..
test the integrity ( do the above yourself to test the discs ) of the files yourself once they are burned ..before sending.
you can make this kind of data exchange as simple or as complex as you want ..( make every third or fifth file available only via download from separate sites etc ..
paranoia can be self fueling :)
btw ..use imageburn [imgburn.com] ..it's not bloatware ..and it's free .and no spyware ..nero on the other hand is huge ..slow ..and proprietary ( paid for ) ..and tries to take over the machines it gets installed on .