Back in the old days...and using a darning egg...I mended my husbands woolen socks by darning them. I didn't knit the socks, but I mended them.
Instead of knitting a new pair of socks, why not just darn them? Seems like it would be a whole lot less work!
Another idea: using the method for mending/darning/patching a sock, you could create a double thickness at the heel or toe, or wherever he is busting through, before he manages to bust the sock out.