What did you find uncomfortable about the horn frames? In theory they should be more comfortable than acetate frames (lighter and they "warm" to your skin).
Have you considered Cubitts bespoke? The quality is good and you'll get a frame that fits you perfectly. You can either have one of their existing models redesigned to suit you or start from scratch with a completely new design.
May be it's the style of it, the rims were rather thick like the JMMs and I didn't get on well with prolonged wear. As to the weight it really didn't feel much lighter than acetate to me.
Cubitts bespoke sounds like a really cool idea, will definitely try that. Many thanks !