One great idea is the activity sheets based on the Disney characters and story behind Disney_Pixar's full length animated film Cars. Easily downloadable from the web, these sheets can be printed in as many copies to be repeatedly enjoyed by any school_aged Lightning McQueen fanatic.
The benefit of making your own puzzles is that you get to choose the topic. Are you obsessed with Star Trek? Then make your own word search full of your favorite Star Trek words and hunt them all down! Is your partner a geologist? Why not make him a puzzle full of geological words as a random present? It's sure to make them smile! Or perhaps your child has recently become obsessed with dinosaurs? You could create a puzzle specially for them filled with words they will recognize, and add in a few they don't yet know to help encourage them to learn more!