First, without "cutting corners", what is the quickest, least expensive way to accomplish this?
Simple, join the military and let uncle sam pay for all you flight training - however, I don't know what it's like in the US but here in the UK the chances of your application being successful are something like 1 in 1.5 million.
Second, what are the physical requirements? Health, vision, etc....
The requirements will vary depending on whether you want to fly commercially or otherwise, there are basic standards but there can be exceptions - I'm not all that clued up on the FAA way of doing things so someone who's more familiar will be able to give you a better idea.
I'm 27 and thinking of supplementing my career.
Some people might disagree with me, but in my opinion you'd better get a move on if you have any ambitions of flying for a living in the US - for some reason the American "system" seems to look unfavourably on candidates over the age of 30, probably due to the fact that progressing through the ranks in US aviation takes forever and a day, with some guys not making their first right seat for a major before they are 40 - here in Europe it's not uncommon to see a 25 year old captain of an A320,757/767 or even A330 with the charter airlines.
[Edited 2004-03-22 17:26:05]
Statistically, people who have had the most birthdays tend to live the longest.