Mitten or socks if you are up to it. Or dish clothes, scarfs, hats, try to find patterns for toys or stuffed animals (they can be pretty cute).
Best I could come up with.... knit/crochet ideas, although some can also be made with other materials: wristbands/sweatbands/headbands hacky sack can/beer cosy one of those golf club socks car seat covers any normal project(blanket, scarf, hat, etc.) with favorite sports team logo house slippers floppy frisbee with sand weighted circumference small guitar pick pouch with belt loops so it can attach to the guitar strap a drum stick pouch that can hang from the drum set laptop dust-cover. like a thin pillow case a short handled ice scraper with a knitted "bag/glove" around it like this:http://www.alibaba.com/product-gs/241461815/Ice_scraper_with_glove.html hamper bag ...padded bong or pipe pouch...
the guys I knit for love fingerless gloves, scarves, and hats... that's the main thing I get asked for, when it comes to winter holiday gifts.
Another idea also is if you look for a book called Knitting With Balls - I forget the author, but it's a good book with knitting patterns for guys... also Son of a Stitch n Bitch is good too, that has both knit and crochet patterns.
Knitting with Balls is a great book! I used it to teach myself to knit. I also like the Knitting (Man)ual. I tend to like mittens over fingerless mittens. Enjoy all kinds of hats. I think the most important thing is to ask him what he wants if you expect him to wear it. See what colors he likes by checking his wardrobe.