what about having him do more with you (the things you need to get done, like dinner, cleaning, etc)? sometimes it's nice to be able to just knock out a job quickly, it definitely takes longer with "help" but it's a good foundation for him learning how to contribute and it really boosts their confidence to be able to pitch in. plus, you know . . . it's something for him to do. :)
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what else does he like to do?
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how often do you have friends over? do you know another family that would want to do drop-off playdates, taking turns with their child at your house, and with him visiting their house without you?
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does he have any interests that he could take a class on, and then have that time slot focused on that activity at home the rest of the days of the week? for example, if you put him in gymnastics once a week at 2pm, then the rest of the week, every day at 2pm you can throw a yoga mat down on the floor so he can practice his moves.
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the problem with all the cute crafts you're finding online, aside from the expense, is that you have to be completely involved. what about just regular old art supplies? you can find most of that at the thrift store (sometimes even paper), make salt dough that he can then play with on his own, and keep your paper costs down by encouraging him to draw on a wipe-able, reusable surface like a chalk board, marker board, or even using something like an etch-a-sketch if you already have one. my kids also make a ton of stuff with recyclables (like the cereal box).
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some other things we like are puzzles, play kitchen, playmobil, matchbox cars, dress up . . . if my boys are having a hard time either with boredness or getting too wild and rough with each other, i will sit them at the table, pull out an activity and say, "we're doing this now." set the timer for 10, 20 or 30 minutes depending on what it is, then have clean up time and pull out the next one, repeat . . . it works! sometimes i have to get them started on it but within a few minutes i can walk away. if i pull out art supplies, i'll often request something specific, like make a card for grandma, draw a picture of our house/family, etc, and from there they will keep coming up with their own ideas.
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i think no tv is an awesome goal, and you can totally do it. however you can also change your mind if you decide it's not working out that well. if you decide that you need, like 30 minutes a day of sanity . . . that's okay. since he talks a lot about the shows and likes to play the characters, just choose carefully, something that you don't mind him imitating, like little bear or caillou. i hope this paragraph doesn't seem unsupportive - i can remove it if you want the thread to be 100% tv free! 