Okay, my second idea, and I think a fun one.
Baby's first computer. My kid is only 2 and 1/2 at the moment, but I know she's going to need her own PC soon. How about in the form of one of her favorite characters; Spongebob Squarepants. Maybe seated, blowing bubbles. (Could even add a bubble blower in there from a cheap toy you can get at a department store.
This would be perfect for a kid's computer so she can play all her favorite DVD's and as well have something powerful enough that she can grow on it and not leave it too far behind after only 6 months or a year.
Construction should be simple enough, mostly modeling parts by hand, materials cost would be low (depending on materials used of course), leaving a lot of leeway for getting higher end parts crammed in there to really help get the most out of a ION.