Hi C.,
My three brothers, father and I all have sleep apnea. We are all on CPAP machines (Boy! is it a mess when we all go camping together! Extension chords running off of batteries EVERYWhere! LOL)
I didn't do well with the full face mask either. It "broke" seal all the time and the air leak was louder than my snoring had been! (Not to mention I wasn't getting the help I needed!!)
There are many, many, many different masks and most of the styles come in different sizes. It doesn't sound like your husband has found the right size/style for his head shape and face yet.
My family all wear what we call the "pig snout". It covers just the nose. The nasal pillow was too easily pushed off of each of our noses since we are all side sleepers. For us, the gel pillow nose mask called, "Profile Lite Nasal Mask" has worked out the best.
The trick seems to be to tighten the velcro headgear just tight enough to hold the mask lightly in place. If it is tightened too much the "snout" really IS uncomfortable AND seems to break the seal even more than when it is more loosely worn.
The masks need to be washed in warm, soapy water every week. When the gel starts to discolor or look wrinkled, it is time to replace the mask.
We have found them on-line much cheaper than we are able to get them thru our local medical supply. However; sometimes the medical supply personnel are trained in helping clients find the appropriate mask and fit...so you might want to check there first. Also, ask about a trial period. I was able to try several masks before actually purchasing any of them---that was a huge help financially!
One of my brothers and my dad had the procedure where the Uvula (the Hangy down thing at the back of the throat)is removed, neither of them has tonsils. Although they did see some improvement, both still need to wear CPAPs and have sleep studies done every two or three years.
I don't know if your husband is a swimmer or into water sports, but, if so, he needs to discuss this with his doctor before opting for the removal of the Uvula. Without this "flap" there is no way to block the water from entering the nose, throat and sinuses. It also took my brother and dad a while to learn to eat without getting choked since the "flap" also helps in opening and closing the right "pipes" while eating.
Tell your husband not to give up. Sleep Apnea is really hard on the heart. He may be fit and very healthy, but the strain of apnea can still cause damage.
V.