A nice dinner somewhere, followed by a comedy club with drinks? Karaoke? Maybe have another couple or two meet you and increase the surprise as well as have some friends to laugh with? Same for dancing as suggested below. Figure out a safe way to get home - maybe call Lyft or Uber so you can drink and not drive?
Make a list of 40 things you love about him or 40 memories. You can make a hardcover book of sayings, memories, photos, anything you want through services like Shutterfly. Have it delivered to a friend's house so he doesn't see it - if you and he share a bank account or credit card, then ask a friend to pay for it so he doesn't see the bill, and just pay her/him in cash.
Don't be afraid to cut back on the material gifs in order to pay for an evening. You can often get a room or a wing of a restaurant for no extra money. Just invite friends to meet you there. You can have a blank book or even a looseleaf notebook - just pass out blank pages for people to sign and write something funny about your husband. For one of my husband's birthdays, I asked people to bring something creative. Some wrote song parodies which everyone sang (they handed out song sheets), some wrote a limerick or little poem, one musician friend composed a drum solo, someone else made a collage....and so on. If you're really organized (or if you have a friend who is), make a video with comments and accolades and good natured ribbing by friends, then edit it together and let everyone watch it that night.
Set a budget, and see what you can come up with especially with help from creative friends.