I have made a few customised travel diaries in the past, as gifts for my family and for myself. See the diary I made for my brother a couple of years ago here. I use Moleskine diaries and print destination appropriate airport codes from baggage labels I have collected on the front. From there I add in extra little envelopes and labels etc throughout which can be used for keeping tickets or odds and ends found along the way.
Normally I print the using my Gocco printer but I ran out of time for this one and printed on some thick tracing paper to add a transparent feel to it and a some Japanese tape...and some extra bits and pieces and it was done.
I mailed it to her and she got it just in time (the day before!!!), and loved it. ;-)