Is there even a process for this?  I have some pretty significant sinus issues and am looking at taking a new medication that is not approved.  I won’t even consider it if it forces a DQ, but if there is a process to get it approved, I’d be interested in knowing what it is.  The FAA has approved it on a case by case basis, but I also realize that they are much more permissive in that regard.  Any help would be greatly appreciated.

Have you tried surgery?  The waiver for return to fly post sinus surgery was fairly quick.  I was DNIF for roughly two months from surgery to waiver approved.  Have had WAY less sinus issues since and that was almost 10 years ago.