N.,
Let him know his Birthday Box will be just a little delayed...THEN you and the kids do a full blown celebration for him, cake, hats, streamers, etc...the WHOLE 9 yards. Have a friend come over and take pictures and video if you can. Get the pictures developed and put them in a photo album or if you are computer savy, make a CD of pictures for him....
make sure you put a baggie of the party favors in the box with the pictures. For gift ideas, I NEVER sent anything that I would be upset if it didn't make it home. I let the kids pick out presents for their dad and of course there were toys and games....so go with that. Just remember the restrictions that apply with customs for A-stan. SO - water balloons, magnetic dart games, checkers, a deck of cards, rubiks cube or similar pass the time game. I sent these things KNOWING that my husband would enjoy opening them and then likely pass the toys and games onto Iraqi children when he went out on missions.
OF course, you don't HAVE to wait to send the box, you can always celebrate his birthday early and then mail it so he will get it on time.
It is amazing the connection your kids will keep when they are celebrating long distance Birthdays.
Good Luck!
T.