No way to sugar coat it -- I have a huge head. The biggest cycling helmets (Bell Triton, Giro Atlas II) just barely fit me.
My hat size is around an 8, but I have been able to make due in most areas, including winter skullcaps, goggles, etc. But I just can't seem to find good face protection that fits properly. Right now I'm getting by with a Seirus Masque which is one of those neoprene facemasks with a notch for your nose, but it doesn't fit very well and I can only tolerate it for a few minutes at a time (makes a decent neck gaiter when pulled down though).
Can anyone recommend a balaclava or facemask for a very large face? I have a Smartwool skullcap that is very generously sized (almost too big) and warm. It would be great if they make a full 'clava like that.
Make a balaklava from an old pair of your woman's tights. Cut the upper thigh area, sew up the smallest opening. Put it over your head, outline the face area to be cut. Remove it and cut the hole. If you want to be fancy, you can trim the cut edges.
If your woman's thighs are too small for her tights to fit over your head, consider yourself lucky.
Thanks to everyone for the suggestions. Recently I found a fleece neck tube made by Turtlefur that fits quite well and can be pulled up over my face and ears. I've also found a few stretchy balaclavas (e.g. REI brand) that seem to fit, but so far the Turtlefur seems like it should be good for temps approaching freezing. I also like that I can pull it up and down easily to eat/drink or to adjust for changing temps.
I have given serious thought about learing to sew and making my own gear, but so far I've been able to avoid that (I'm assuming that my head won't grow any larger, at least not physically ).