Hooray for papa wearing!
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I also like the idea of a wrap, or a mei tai with very long straps. I think those would be the most customizable for a large dad. I don't think you should make or buy a stretchy wrap, though. You said that you want a carrier that you can use for an extended period of time, and a stretchy wrap will probably only for comfortable/supportive enough for the first few months.Â
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I know more about wraps than mei tais so I'll just give a few more tips on those here. Woven wraps are AMAZING because you can use them to carry the baby on your front, back, or hip (unlike a stretchy wrap which is only safe for a front carry) and they are supportive enough to use even with preschoolers. I know you can find a size 7 (5.2 meter) wrap pretty easily on the For Sale or Trade board on the TheBabyWearer forums. I've also seen a few 6 meter wraps for sale, but 5.2 is the longest size I see regularly. 5.2 meters would probably be long enough for a plus size woman to do a multi layer carry, like a front wrap cross carry. Your husband sounds bigger than that though...so I imagine 5.2 meters wouldn't be long enough for him to do a multi layer carry. It might be long enough for a single layer carry, like kangaroo for a front carry or ruck tied in front (rtif) for a back carry. Just put in "kangaroo carry" or "ruck tied in front" on youtube for tutorials on how to do them. I think it would make the most sense for him to do single layer carries, because the amount of fabric he would probably need for multi layer carries might be overwhelming.
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If you can't find a woven wrap that's long enough for him, I'd suggest making your own out of Osnaburg fabric. The women on the DIY section of TheBabyWearer would have a ton of advice about that!