Oh, ok, I just don’t usually hear it called that.
Without money you are going to be somewhat limited. Everybody does the typical behind the scenes interviews and backstage/studio footage thing. If the artist travelled someplace on tour or while composing the songs that was interesting, a little travelogue with lots of cool stills could be neat.
Say the person played blues, a tour to the old Chess studios would be of interest to fans and a wider blues audience. If they play folk instruments, a visit to the place their guitar or whatever was made could be cool.
A quicktime VR panorama of the group on stage, that you can navigate all around to look at from different angles, could be neat. Add some extra work and embed tags in various target objects in the panorama that are links to hidden, full pages the web site, or just to some HTML pages on the give-away disk with more detail about something. Like click on the amp in the corner to get a list of all the instuments used inthe making of blah blah blah.
Record some audio stories of the origins of particular lyrics. Add flash animation illustrations.
How about you supply a version of one song from the album in a format where the user can re-mix it and mash it up? You would have to prepare the tracks so they would be ready for use in a looping program like Acid or etc. This could also be duplicated on the web site. Then you run a contest to enter your best re-mix of the artist’s song, and that one will get added to later pressings.
Simple: add alternate templates for the CD cover so you the owner can print out the cover you prefer for your CD.
Maybe change the form it is delivered on: put it on USB keychains instead of a DVD or CD-Rom. At least for a handful of high-profile target viewers.