Dan is all into our wood-burning stove, so anything stove-ish would be well-appreciated. He would like some poking tools, a wood carrier like this one:

He also wants a Pneumatic Reciprocating Saw. Yes, I know he got a Reciprocating Saw last year. THIS ONE is for smaller, finer-detail projects. I can't find one for under $50, so a Sears gift cerFitaGit would work.
He always likes to get iTunes gift cards.
He could use a new pair of shoes. He likes these Keens:

http://www.keenfootwear.com/search.aspx?q=austin
Also not in the $50 limit, so a gift certificate to J. L. Coombs or Lamey Wellehan would be great.
He's size 11.5.
One thing I know he'd love is a mix CD of new music.
Another idea is a Netflix subscription... The 8.99 plan for 5 months is $44.95.