FPGA costs have come down like crazy in the past few months. Our dual boards do 200 Mhash/s for $610. If we are able to hit an order size of 1000, cost will come down by $50 or so. If we get the automatic overclocking software up and running, then it will be something like 280 Mhash for $550. At 15 watts or less. Sounds competitive to me.
My opinion is, we aren't far from seeing FPGA order sizes hitting 1000.