Before my husband went to Iraq we had videotaped him reading a few of our sons favorite stories. We also bought a small tape recorder (one that uses regular sized cassettes) and my husband took it with him. My husband recorded himself talking to our kids and me, like a talking letter. Some tapes were just specificlly to our son so that he could play them on the music player in his room whenever he wanted. My husband also called and left messages on our answering machine that we never erased but played over and over whenever we wanted to hear daddys voice.
We never ordered one, but there is a company that makes "Daddy Dolls" they are 17 inch tall pillows that have the deployed persons full length photograph on it and the pillow is shaped around the shape of the photograph like a persons shape. But I'm sure a local company could apply the photograph onto some material for you that you could make into a pillow on your own. http://daddydolls.com/products.php?PHPSESSID=14f60982aee1...
Something we wanted to do but never got around to doing in time (We only had 2 wks notice before daddy deployed) was we wanted to go down to Build a Bear and make a bear with daddy recording a special message for each of our kids. They put the recording inside the bears and you can squeeze them to play the recording.
Some people make a paper chain to count down the days until daddys return. We made a candy chain. We got plastic wrap sections about 2 feet long (long enough so that each section was 2 weeks of candy increments) and cut them down the middle lengthwise. Then we took small individually wrapped pieces of candy and spaced them out along the plastic wrap. THen we rolled the plastic wrap up with the candy inside, jelly roll style. THen we took 6 inch lengths of curly ribbon and knotted between each section of candy and curled the ends. We tied each 2 week section together so that there werent any gaps in the chain. We hung the chain up around the walls in the playroom. My son cut off a piece of candy every day to mark another day closer to daddy coming home.
My advice would be to use a variety of candies, assorted hard and chocolates. Also include small items in addition to the candy such as party favors or tiny gum ball machine toys. My son actually got tired of candy and didnt want to eat it every day. He still cut the candy off, but put it into a jar 'to share with daddy' when he returned.