That does sound uncomfortable. Your husband is on the far-right side of the bell curve, size-wise, which means that he聮s always going to have a hard time finding a pack that fits. That聮s especially true for a daypack, which is what I infer you聮re after. Most daypacks come in only one size.
Atmos 50
Still, there are some alternatives. Osprey聮s Atmos 50 ($199; www.ospreypacks.com) is an excellent big daypack (3,000 cubic inches of capacity) that comes in three sizes聴small, medium, large. The large will handle torso lengths of up to 22.5 inches (torso length is basically the distance from the top of the hipbone to the base of the neck). That should be very close to what your husband needs. Gregory聮s large-size G Pack ($139; www.gregorypacks.com) goes to 21.5 inches, which also may be big enough but will be a bit of a stretch. The G Pack has a little less capacity than the Atmos, though, so it might be a better choice for a daypack (plus it costs less.)
Lastly, Arc聮teryx聮s Bora 50 sports the ability to handle torsos up to 23 inches, making it one of the “tallest” packs out there. It聮s a mid-sized pack with about 2,800 cubic inches of capacity and excellent suspension. Alas, it聮s also rather dear at $245 (www.arcteryx.com). But a great pack!
Your husband will need to get into a camping store that has a wide range of good-quality packs, and try on several. I think he聮ll eventually find one that聮s just right.
Check out 国产吃瓜黑料 Online聮s for a look at the haulers to get your gear from A to B regardless of your body shape.