I just saw sunscreen that is supposed to feel dry when you put it on...I think it was at Target, maybe made by neutrogena?
Also, I love Clinique's sunscreen (spray or lotion). Some sunscreens work by sitting on the skin, these feel greasier and I don't like them very much either. Others rub into the skin...and feel better, silky smooth. Clinique's doesn't smell as bad as some others I have used in the past.
Or, maybe you can make it fun, see if he will let you use one of those that go on colorful and then disappear when they dry. I think Coppertone makes one, I have some from Avon that also has bug repellent in it.
Good luck...my DD 2.5 hated any sort of lotion (not just sunscreen) for months and just recently came around to letting me put it on her. (Thank goodness).