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I called Trend, and they sent a new headband free of charge for my 10 year old unit. There are a number of threads on the various woodturning forums that address building battery packs. Also a good idea to buy a “smart charger” for about $20.00. I’m on my original battery packs and get 6-8 hours per charge.
Call them. They replaced my control box (on/off button unit) pretty quick and no charge. My head-band I wrap foam around, with out it, makes my forehead hurt. I think I saw sometime back a thread about building battery packs for it, search for it? Looked fairly easy.