I was just surfing around in search of something completely different and stumbled upon a jigsaw puzzle quilt pattern!
It's kinda pricey - $8 - but you'd probably spend at least that much on kiddie puzzles to make your own templates.
http://www.virginiaquilter.com/cgi-local/SoftCart.exe/online-store/scstore/p-JGSW.html?L+scstore+cjrs0207ffde62de+1169156643