Mate it could be you have a prominent arcus superciliaris (commonly known as supraorbital arch). A potential solution can be to squash down the foam or dremil it away. Not recommended nor advised but possible and if it is just a bit may assist in making it comfortable.
I know that my cage helmets always needed - CUSTOMISATION in order to avoid this same issue. A few weeks of 'sweating it in' (like 'wearing it in') often helped.
I hope this helps. If not, fit your helmet and run around naked in the snow. Chances are you wont feel the sore bits on your head!