Gaz, I'm not entirely convinced it's helmet fit only. I sometimes get a 'pressure' headache, but that's when the helmet is too tight.
Anyway - have you taken any paracetemol to get rid of the headache ? - It's good stuff.
For that 55 miler, at a good speed (I checked your garmin stats
), you should also be eating real food. 3 gels and two bottles - what was in the bottles ? Argh - sugar !
The gels and energy drinks are relatively quick release carbohydrate - i.e. you'll use them up quickly, but won't be bad like pure sugar and cause a massive insulin hit - it's slow enough not to cause a big rise in insulin production. I'd never recommend anything like sweets/choc/coke etc on a ride as this will kick in insulin to level out this sudden sugar rush, and you'll be a in a worse place after.
As a youngster, I only did this once/twice within my first year or two. Feeling bad, real bad, lights flashing in my eyes, grabbed a couple of cans of coke from a butty van at the top of Long Hill. Felt great for 5 miles, then a massive blood sugar crash. Far worse. Crawled home. Repeated that, on one of my first 25 mile TT's - some mates gave me some Kendal Mint Cake part way through, absolute mistake (if you've never had it, it's minty sugar - certainly not a cake).
Fortunately I soon sorted my ride diet, and most importantly the race diet.
Most important to any ride of 3 hours and above is pre ride food - ideal is oats/musili or some decent cereal, maybe some toast, some fruit and wait for it, plenty of fluids before hand. In the morning you are de-hydrated, so it's important both on long rides and on the commute to drink.
I even drink a bottle of water over my 11 mile commute in the morning
I can only compare what food I eat over a 100 mile sportive.
3 litres of energy drink, 4 gels, 4 bananas, a malt loaf broken into 5 servings, 4 oat bars. Only the banana's were from the feed with energy drink top up. Gels, malt loaf and oat bars were in my jersey pocket.
Pre ride was big bowl of porridge, 2-3 bananas (on top of the feed station ones), tea, and then 2 bottles of drink - one driving to the event and one whilst getting changed. All this meant I was able to ride at a very good pace, no sign of any 'bonk', and was fine at the end.
Regular headaches - something is a miss, certainly have a chat with your GP. I think the Helmet thing is a co-incidence.
You are at a point where you don't have that much body fat to keep going, you've got there, but now you'll find you need to eat a significant amount of food. I reccon, at high intensity cycling, you'll burn 800-1000 cals an hour. So as a minimum, you need to find 1000 extra cals every day if doing a good work out when commuting.