The suggestion for using extra wide fabric is great. If you don't mind using a seam then do a fabric search for "Quilts of Valor". All of the primo fabric manufactures came together to do patriotic themed fabric this past year. You could easily piece strips of patriotic fab together for the top and extra-wide fabric for the back. Robert Kauffman has military fabric as well.
If he is absolutely against taking a quilt with him then you could always donate it to the Quilts of Valor in his honor. They give quilts to wounded veterans.
God bless him as he serves and God bless you as you wait for him to come home.