Some random thoughts:

* Give him good meals before each flight (not necessarily RIGHT before, though, because many kids get more active after they've eaten).

* Magnetic toys can help. We have one that has a magnetic board and lots of magnetic colored shapes. I'll send the name after work this evening. This one kept my kids pretty happy for an hour or more each on a long car trip over the summer. Magnetix are good, too (get sets with oddly shaped pieces).

* If you buy new toys just for the trip, do NOT allow him to play with them until you get on the plane.

* Highly engaging games that can be played alone or with others (YMMV on the definition of "highly engaging"): Some that work for us include Shut the Box, Camouflage/other ThinkFun games, Set, and YamSlam.

* New books!

* New Lego sets if he's a Lego-y kid.

* Carry lots of nutritious snacks

* Does he have a DS or similar handheld game? These toys can be extremely engaging. I think they're good things in moderation.

Hope that helps...

Val