I was thinking maybe lego (too difficult?), Duplo (too easy?), K-nex (don't really know what this is, but have seen it in the shops)...basically something along those lines that he can build loads of different things from.
They have something at his playgroup that is made of of loads of cubes and long bits that you click together and he spends hours playing with it, but I don't know what it's called.