My son suffered daily headaches and although I wouldn’t say this was a the sign of a crisis, it certainly has been proven that it was down to his SWCAH control. He too has had an incredible amount of hospital admissions throughout his life at one stage it was monthly occurrence. He became so ill they wanted to admit him long term.  He would also sweat an awful lot and would easily go bright red in the face. He was at one stage on over 100 mgs of hydro given over 7 doses a day.  Extensive tests showed that he was metabolising the hydrocortisone very quickly and he was not absorbing the hydrocortisone properly. His headache became constant.  His levels were out though although this only became apparent in puberty.  He once had surgery and was in ICU after due to the fact he needed extra hydro but was not given in it, and the sweat was literally pouring out of him although he was barely conscious.  Once my son started on the pump, his headaches cleared up and he no longer sweats excessively. I am not sure if this info is of any use to you, but I wonder if your son may benefit from perhaps 4 doses of hydro a day?  Has he ever had a 24 hour cortisol and 17 OHP profile?