What about Bitcurex? Anyone try their card?
http://shop.bitcurex.com/index.php?id_product=10&controller=productAbout 2.5BTC for either a re-loadable prepaid visa or mastercard. Apparently you can send BTC directly to it and it converts them from bitcurex last to your currency. The exchange seems to be more of a buyers' market than mtgox, and the fees are fairly high, but it seems to be a reliable option for those who really want such a product.