Hiya Ben
I haven't read all the postings here so sorry if I repeat anything.
Like yourself, I too am blessed with a large brain (!!) and have a pig of a job getting a comfy lid.
I have a KBC 'TK 9' full face (I think it's XXL) and it's great. It's about 12 months old and, when I was having bike lessons a year or so ago, the instructors suggested replacing lids every couple of years anyway - depending on use.
May sound over the top but they do get dinked and knocked and you only have one head right??
Good luck in the search.
Ride safe