I made my hubby a pillow from a shirt of my daughters that he loved on her when she was little. It was a printed t-shirt that had a silly saying on it "boys are icky"... he loved that shirt on her so I put a cotton fabric back on it and stuffed it - he loves that pillow and it is just a throw pillow for our bed :D
If he has some favorite shirts that he has outgrown - you could make him a t-shirt quilt from them.