We have an eclectus who has this exact same problem. There is no real "cure" for it. Just try to make sure there are plenty of both hard and soft woods to chew (as it sounds like you already are). Some birds will injure or damage their beaks at an early age and it will cause a part of the beak to grow in an odd way. I am guessing at his/her old home that maybe there weren't enough toys offered or at sme point the beak was allowed to fully overgrow, then it does seem that it is much harder to keep the beak even as it should be. Sometimes the birds are completely healthy other than the odd growing beak. Have you had your bird thoroughly checked by your vet? The only reason I ask this is that sometimes a liver problem will cause the beak to grow more rapidly (but usually this is the entire beak not just one section). If this keeps happening you might ask your vet to show you how to use a hand grinder to lightly grind down that edge of the beak. If your macaw is healthy otherwise this would help keep his beak trimmed and then you would only have to visit the vet for his checkups or in case of illness.

Sorry I couldn't be more assistance.

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