Find a cloth with a pattern in it, and he might like that, or one that's knit on the diagonal like Grandma's Favorite. There's a lot that use knit and purl to created designs. Check out these sites -
http://www.knittingonthenet.com/cloths.htm
http://www.knittingpatterncentral.co...dishcloths.php
Dishcloth Boutique
On the first two sites you might find a hat pattern that's knit flat, then sewn together.