Here is what you can do. Mears doesn't provide the $29 RT fares from Disney resorts because of ME, BUT they do provide the fares from the Swan and Dolphin.
When you arrive at the airport before getting on Magical Express, drop by the Mears counter and purchase a roundtrip to the Swan. (It doesn't matter if you aren't staying there). The vouchers will be in reverse order from what he needs, but it doesn't matter.
The night before he has to go to the airport, call "0" from any house phone (your room phone is a house phone) and ask to be transferred to Mears, once he is connected to Mears, he can give them his flight information and that he needs a pickup from Swan. They will tell him what time.
He can then take Disney transportation over to Disney Studios, then walk or take a boat to the Swan. If it is very early in the morning, then he may need to take a cab to the Swan.
When he returns to MCO after his trip, he then drops by the Mears check-in area with the 2nd half of his voucher and he will be returned to the Swan. He can then take a cab or Disney transportation back to your resort.
Any other transportation (cab, towncar, will be significantly more expensive).