Chaosmagnet, thanks for the info about the Niteize band, oh well. Pforeman, the Storm looks nice, but I think we're looking for very light and tiny lights here, like under 1 ounce including batteries and strap (the Flare and e+LITE both fit this). The Storm is over 4 oz so is more full size. The only thing wrong with the Flare seems to be that stiffener in the strap: I wonder if they really need that. Oddly, REI has a bunch of BD models but not the Flare, so I can't go look at one there.

I've gotten some nice tiny zipper pouches at Daiso that I use for things like earbuds. They weigh just a few grams and a Flare or a 1aaa light and strap might fit nicely in one.

Hmm, the Fenix HL10 goes a little over the 1 ounce limit (40g with L92 battery) and it may be discontinued, but it is a 1aaa right angle design like the Manker. I personally find it a bit ugly and would change a few things to make it smaller:

https://www.fenixlighting.com/product/fenix-hl10-headlamp/

Added: Fenix HL05 is another 2xCR2032 headlamp, now discontinued though you can find them if you search around, 29.5 grams including batteries and headstrap. Reviewed here: https://budgetlightforum.com/node/42621

I think it would be a contender if it came back at the original $15. I wonder what it would take to get Fenix to bring it back. There is a surprising scarcity of this style of light.

Another addition: I'll mention another light not because I'm recommending it (it is a usb rechargeable and has various implementation flaws) but it seems noteworthy as a step in the right direction. It's the Nitecore NU05 which is basically a 1 inch square with SMT leds, an internal battery, and a belt loop-like thing on the back that can thread through an optional headband. There are tons of reviews etc. online.

The light weighs just 10.4 grams and the headband might add another 10g. It has 110mah 3.6v internal lipo cell and runs about 1 hour at 35 lumens, i.e. I wish they had added a 3.5 lumen 10 hour mode. It also has green and red leds with flashing modes etc. Because it is so small, rather than spare batteries you could really carry a whole additional light, so you'd have a spare if something went wrong (you probably wouldn't have a 2nd headband). A Photon Freedom weighs about 7g so with a second NU05-like light you could leave the Photon and its extra batteries out of the kit, and basically break even on weight.

What we actually need though is a CR2032 or (better) 1AAA powered version of this light, with saner modes.