That's great! Thanks guys! I've definitely got more to work with now and am starting to pair up some of your ideas with specific people.
I did find one thing to make on my own - a puzzle box shaped like a knight crusader's tomb (not exactly D&D - but one of our gaming buddies has a big chivalry thing going). Anyway you could easily alter the symbols on the side and the figure on top to be almost anything, and I may go with something more gaming related. And it would be a sweet place to keep dice, figs, or whatever.
There are instructions here:
If you're at all handy, it's a much easier project to assemble than most puzzle boxes, as it's just 1/8 inch plywood cut into strips or squares with a few notches and glued together. No router or other complex tools or techniques.
Yay! I'll finally be able to give them each something different!