So this is what they ended up looking like:
PJ's are another Christmas pressie.
I just love those little starfish fingers...
...and the concentration needed to build a tower.
I ended up using the Actopus to Zelephant scrap book papers. 2 sides have the alphabet letters - the size of the alphabet paper is absolutely perfect for 5cm blocks. 2 sides are puzzles - rather advanced puzzles I must admit (frogs on 1 and butterflies/leaves on the other). 2 sides are just patterns. But all sides are great for grouping and sorting activities. Daddy tlf kindly filled my previous dremmel botch and sanded the blocks nice and smooth and I modge podged all the paper on. It didn't take too long, but was still quite a time consuming project for evenings only.
Now I just have to figure out what to store them in. I had planned on sewing a draw string bag for Christmas...but that was one of the time-casualities.