Alternative methods of merging fields in mailing

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Our client uses a lots of custom fields that are basically used in email - merged fields. In fact the only reason they have so many is because they are using them for emails to their customers. Actually their custom fields of Contact object have reached the max limitation, they can't create any custom fields anymore. But they still have new needs to create Contact custom fields to accommodate data. 

As we know, RightNow Mailing can only merge fields into email, but these fields belong to RightNow primary objects such as Contact, Incident, Opportunity, Organization etc. Custom objects can not be merged into email. Although merging report is another approach, it is not a good alternative to merge fields.