Thanks for all the great information. The head aches usually occur about 15 - 20 min in to the dive. The pain is strongest at the top and back of his head so I don't think it is sinus related. This guy is in amazing shape works out everyday. I don't know about the hydration I will ask.
B.
Doesn't mean anything in the water. Even the best cardio runner will take a CO2 hit if they're flailing or constantly hauling tail at depth on scuba.
I hope it is CO2 retention for your buddy. You can fix these sorts of things pretty easily, all it takes is an eye opener and a willing diver