Do not send anything which is not good under hot conditions, nothing which can melt. No perishable toppings/fillings. Homemade shortbread or cookies would be good as they last longer, easily packaged and light to post. Cakes might lose there moistness.
How about some decorated sugar cookies in the shape of cupcakes??!!! lol There are cupcake shaped cookie cutters available that are cute as a button. If you make the cookies pretty thick (like 1/4") and with very careful packaging, they should reach him safely.
I've seen people send "canned" cakes. And they're supposed to be yummy. Look it up. 
When my husband was in Afghanistan, I would bake brownies, cookies, breads,etc... freeze them. After them were frozen and I had enough for an APO flat rate box, I would ship them. By the time he got them, they were defrosted and ready for him to enjoy. He said that all the stuff lasted for days and was still moist. Hope that helps.
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