Hi Mark,
I am not sure of the final US destination but if they can skip HNL you can often get business class fares on either United or Delta for $4500 return SYD-LAX. These need to be purchased 50+ days in advance. Both UA and DL offer full flat beds. DL is a bit better as each seat has direct access without needing to step over anyone or anything.
If HNL is to be included then look at Jetstar and American Airlines using a KUP fare (instant upgrade from Y to F fare). However this is not going to be as good as the direct flights on either UA or DL and is more like a premium economy than a business product.
For East Coast you can often get over 60 companion fares on many of the Asian airlines one stop to New York or companion fares on EK and EY to New York. The other option for the east coast would be a Delta fare with a KUP AA fare.
Preference at work was given to VA for US travel but price wise they seem to now be on par with QF. This is a shame as they do have the best product on the route.
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