For everyone who's following this thread, this message contains
instructions for what is either an instant solution, or failing that:
the very-near-future solution.

No worries Mark!  Honestly, this sort of thing drives me up the wall...a
"computer", by definition, is supposed to take input from somewhere,
feed it into an equation, and then *always* output the correct result.
Computers just aren't computers anymore, when they fail us...  So for
myself, it's back to a custom kernel, like the "old" times in the '90s.
As for everyone else:

If your NIC worked in Hardy, it will work in Karmic, just about
guaranteed.  Karmic is linux-2.6.31, and b43 works just fine in
linux-2.6.30.  As linux-2.6.31 is still in pre-release, I wouldn't
recommend tracking the Koala's kernels...  There's still one thing I
haven't tried -- The soon-to-be-released Jaunty 2.6.28-14:

http://archive.ubuntu.com/ubuntu/pool/main/l/linux/linux-
image-2.6.28-14-generic_2.6.28-14.47_i386.deb

I'm linking to them directly so that no one has to enable to "proposed"
repository.  These kernels are currently in jaunty-proposed.  I haven't
looked at the 2.6.28-13 to 2.6.28-14 patch very closely, so I don't know
if the B43 driver in this kernel is from linux-2.6.30; however the
kernel team is working hard to backport a functional b43 driver!  Now is
the perfect time to test this new kernel, and help the kernel team shake
out any remaining bugs with the backport of a better b43 driver.

Oh yeah, here's the hack I use, because I don't use Network Manager:

1. put b43 in your /etc/modules.  My BCM4318 takes so long to initialise after 
it gets the firmware that it ignores the networking commands it gets from 
/etc/rcS.d/S40networking....  But /etc/modules is the easiest place to load the 
firmware early (trust me, I've been tinkering with custom initrd images for the 
last hour)
2. You're half-way there.  If you use Network Manager, than that's it!  'hope 
it works for you.
3. If you don't use Network Manager, wicd, etc, and have your networking info 
permanently stored in /etc/network/interfaces (this is the opposite of a 
"roaming" network profile), then you might want to try making these 
modifications to /etc/rc.local

first, remove that exit 0 line if you still have it -- it's no longer useful.
then add the following towards the end of the file:
ifdown wlan0; sleep 2; ifup wlan0 &

Obligatory car analogy: when you jump in your car in the morning in the
middle of winter, turn the key, and your car doesn't start -- oh, your
hear the engine try, but it turns over just once before going back to
sleep...well, the "ifdown wlan0" is when you back off on the starter,
"sleep 2" waits for two seconds, and then "ifup wlan0" gives it another
go.  Yeah, it's a hack, but at least it works reliably for me... 'hope
it works for you.

WHOA!?!  Jaunty-auto-update popup.  linux-image-2.6.28-14 was just
released...if it didn't fix b43, make post the latest of all the logs
you're supposed to.  Last-minute post-release minor bugfixes are quite
common 2.6.28-14.46 to .47, and maybe a .48 if it's needed.

-- 
Post-Hardy regression: b43 and bcm94311 disconnects due to PHY transmission 
error
https://bugs.launchpad.net/bugs/263106
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