I made another 3" x 5" index card sized player character sheet, this time for Labyrinth Lord. Much better this time, I'll have to go back and re-do that Swords & Wizardy one. You can get it here.
Update: I changed the header font and title, and added trademark information (not reflected in thumbnail image here).
I'm using these as 4"x6" cards, I just scale to 120-122% during printing. There's some wasted space at the top and bottom, but they're much more readable and at the moment I can't be bothered with re-doing the whole layout for a true 4x6 card.