Does anyone know of a small handheld flashlight that can be transfrormed to a headlight without adding anything to it? So it could be used for one or the other at any time.
Have you looked at the Zebralight "H" series of lights ? Lots of choices (battery type, flood/throw, brightness), and they are good quality lights - I have two already, and am waiting for two new models to be released to buy (H51 and SC60).
Buy a hat and some industrial velcro from a big box store. They also carry specialty holders for flashlights to be worn on head.
If you were getting fancy with a head, you could try some heavy duty 6 gauge ( I am guessing at gauge) wire for your position adjuster. I havent tried it yet, but have some in the basement that I bought. I have tried the industrial velcro hat, which works well, but looks ridiculous. You need to weigh effectiveness v. appearance.
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but seriously, the torch that I've found most easy to make into a headlight without the need of specialty bands, extra clips or Velcro has been the fenix MC-10. It comes with a clip and the adjustable angled head makes it quite nifty. I only wish it was a bit lighter.
Funny enough, the MC-10 doesn't actually fit in the Fenix head plate of the HL-20 but you can just clip it on the band anyway.