You only need to count him in the household size if you claim him as a dependent on tax returns. If you’re not, then he is not counted in your household.
Secondly, you might not have an issue here. Tax returns are not an indicator of CURRENT income. CURRent income is demonstrated by paystubs and an employment letter. So, let’s say my 2023 tax return shows 0 because I was unemployed last year. However, this year I found a job making 200k. As you can see I’m making well above and I can demonstrate that with paystubs and an employment letter even though my 2023 tax return is 0. I hope I’m making sense. So if you’re NOW currently are making well above the threshold then you’re qualified financially.