It's been 6 years since this thread has gone up, but I am so happy to read about other people who know about "i want to cut open my eye/eyebrow and release all of its contents" type of pain that I knew I had to post a reply. I basically suffer from this 30% of my travel time, usually terrible and once in a while "i think I will just faint from this pain" terrible. Most of my episodes last for a few days, a few for weeks even.

and to all those who wonder if something does blow up up there - the answer is yes. I had one episode where (I think) one of capillaries cracked open so I had a very visible vein running from my forehead to my nose for a few days. In another episode, capillaries near my sinuses got damaged (again, my humble opinion) and there was a bloody mucus discharge to my throat for weeks (woke up spitting blood every morning.. not the best way to start your day).

Holding recurring sinus troubles in check (antibiotics every 2 years) and decongestants help. I also started wearing a winter hat during flights to keep the area warm, which doesn't help 100% but makes the pain less intense..

So next time you see someone walk in to a flight with no hat on and put one out in panic midflight, just smile.. no we are not crazy.. just in great pain.