When I got Dorian and it had been a year he was still afraid of my hands, biting when he felt I wasn't listening to him, which in turn made me afraid to put my hands anywhere near him. He was not stepping up, and still totally cage bound, So I got desperate and hired an animal behaviourist to come over for a couple of hour to observe us and 'talk' to Dorian. The best advice I got from her was to approach him as if he was already the bird I wanted him to be. With the stepping up that meant to offer it as an option to him and allow him not to choose it right now. Same with being cage bound. I left his door open and allowed him to choose to stay inside that day. As silly as it sounds I became aware that I approached his cage with different body language when I kept this advice in mind. It was a few weeks of this and he became noticeably less bitey, and one day he left his cage and had a little wander round the outside! I really believe my change of attitude made him feel safer.
Have you checked out the tread, in the training room I believe, called Behaviour Most Commonly Seen, or something like that. It will help you pick up on your birds subtle body language before they get to a bite. My Dorian usually wakes in a lovely mood, but every now and then he wakes up on the wrong side of the perch, and I now can tell before I even open the cage door. On those days I don't offer my hand for the inevitable bloodletting. You need to learn your birds body language so you can cut him off at the pass before he gets to a bite.
Part of that is keeping him off your shoulder where you can't see his body language. If you have to get creative, do. Maybe sew a stuffie to each shoulder so there's no room for him? Has anyone ever taught you the Egyptian pose? If he lands on your forearm, drop your elbow so it's lower than your wrist. It goes against their instincts to climb down. This worked for me. Dorian used to try to climb to my shoulder all the time. Now that I'd actually trust him on my shoulder, he's not at all interested! When you hear flapping wings put your arm out as a place to land. If he lands on your forearm go into the Egyptian pose, if he lands on your upper arm immediately put your opposite forearm in his way blocking his path to your shoulder as was suggested above. If he does get to your shoulder, have you ever tried getting him to step up onto a perch? I've trained Dorian to step up onto a perch and now he does it obediently 99% of the time. I use it if I want to move him from a place like my desk, or his playstand at bedtime, but he isn't in the mood to obey. They can get in downright pissy moods at times. I usually give him one chance to do things in a civilized manner, then I bring out the perch. To be clear, he's not at all afraid of the perch, he just seems to recognize that he's pushed mommy just a little to far at the moment and steps up for it. I even give him a minute to take out his frustration on the perch when he's been returned to his cage by grabbing it by an eye hook I've got screwed into the end of the perch and beating up on it for a minute. That part is quite cute, but I'd never tell him that!
As for his fear of men, have you ever wondered if a man did something that scared him badly while he was in transit to you? I don't think a reputable breeder would have shipped a bird with this intense a fear response. You may never know what happened, but anything you can do to bring down your birds' overall fear and increase his confidence will help his reaction. When I rescued Dorian his previous owner told me I could never date a man with grey or white hair because Dorian reacted so badly towards them (her husband had white hair). But then again Dorian was overall a very fearful bird. Now he's such a confident little bugger I doubt he'd even have a reaction. Anyway, for this reason I don't think I'd clip him right now. He sounds like a very fearful bird. You need to increase his confidence in his ability to handle situations that are frightening to him. Clipping would do the opposite. By all means put the travel cage out where he can get used to it. It will come in handy if you ever have an emergency. Let him explore it when there's no emergency and he won't freak out by being put in it if there is one.
Sorry, this turned into a long post. I hope there are some tips here that you can use.