How often are you feeding him? I didn't see a response to that part of the question above. Upping his prey size is less efficient for his body to process than feeding smaller prey more often, which means he could still be aggressive again before the next scheduled feeding day.
Secondly, I know you said he is set up properly according to "BP manuals," but I haven't seen anything printed in less than an $80 book that was as helpful as the caresheet on this site. I'm not asking for you to go through and tell us all your settings, but please review them with this information in mind:
http://ball-pythons.net/forums/showt...ius)-Caresheet
I would definitely add another cave-style hide to his enclosure - the log style doesn't really offer much security since it is open on both ends.
Added: You can always get a snake hook for getting him out of his cage, even though you of course want to find the source of his stress. Even though he seems huge, most fear "bites" are more like him hitting you with his mouth (not biting), which won't harm even a teenage boy.
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