by Ken Task.
Sounds like you need to look into a template course - can copy that without issue. Copy is just that ... everything. Then add to that template when copied.
Excluding large files ... step through a backup of the course where one can de-select the large file links - might also exclude users. Restore that backup as your template.
Those 'large files' could be held in a 'unirepo' - 'universal' file system repository - that all moodle sites could access if set up that way. All links to those would be the same in all courses/sites.
Above is just one idea ... am sure others might have their own 'methods of madness'!
'SoS', Ken