Bantha - I had the same problem with the eyelids, the thickness distorts when moving the eyes around, I tried using the morph tool, which helped a little, but not enough.

TheDoctor - amazing work, and in so little time! I will check out FaceGen - for my purposes, the mesh shape will be most important because the figure will not have a skin texture. My only concern with this method is being able to use talk designer with the new head.