i bought one of them tripple led headlights, with a BIG head, it runs off of 3 aaa , i just pulled its reflector piece out, and the 3 light board, and shoved a 12 led array in instead, it has worked great.
but its not "comfortable" i put it on to have a head light.
one time they had a glasses type frame , with 2 AAAs on each side, and a penlight incadescent, that was very comfortable, even though the light was very bad.
then i got a few of those hat clip/head band things that are 3AAAs and 3 leds in a cylinder that stick out straight out from the headband, they were not bad.
but the same problem existed in all of them, having all the weight on just the front, batteries and assembly. the headband then either has to be crushing your head, or its falling off during normal activity . its not like people are using them watching tv in thier recliners
so the best IDEA that i could think of to MOD the manufacturers stupidity, would be to put a Luxeon star on the plastic base of thier headband, with or without optics.
then either put a 3 AA battery module on the back , or around the headband, or put the pack down on my belt, or even in my pocket.
you can get a cruddy 4AA holder at radioshack for little, that fits in the pocket good, i made a few quick led lights with them.
i dont wory much about water resistance (in california) everything dries easily, and Low-voltage will work totally exposed in fresh water without a problem.