Oh MinxKitten, so sorry that your husband is having such a rough time! And I know what you are going through.
I got involved in my husband's condition this summer because he has had the worst cycle ever. What I have learned is that cluster headaches can really change their pattern - time of year, intensity, duration, frequency, everything. Before dh's cycles were extremely predictable but this summer has walloped that. This summer he had some super long headaches that caused him to crawl around crying and vomit with the pain

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I couldn't stand it. My theory is that changing allergy patterns are involved, but I have no way of knowing whether that is true.
It is a great thing that you are involved. My experience has been that dh has not been able to be proactive about his medical care when he is in cycle - too drained by managing the pain and coping.
Quote:In the past he's tried O2, kudzu, that pepper nose spray, imitrex, red bull regimin, and more. all have little or no effect this time.
This is very important. Many people come to this forum having "tried" O2, but it turns out they didn't do it right. The
bare minimum is 15 lpm with a non-rebreather mask. Better is following the directions at this link to the letter:
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Did your husband try O2 this way? After my husband's most horrible night, I became determined to get him O2 the next day and I somehow pulled it off by begging a lot. It has been a lifesaver for him...I don't know how he would have survived this cycle without it.
more good info about O2 here:
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Quote:I made an appt with our GP tomorrow to check some blood levels like D and other things to see if there might be something causing this severe pain level.
That is so great that you are getting his D level checked. In the meantime, I would start the regimen including the loading schedule. Scroll down here to see what you need to buy at Costco:
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The reason I encourage this is that some people start responding in DAYS. My husband took longer, but in 2 weeks, my husband went from 2-3 hits per day, to 1 hit per day. After 4 weeks, my husband is getting more pain-free nights than not. The regimen has a great success rate and if it works then the person probably needs it anyway. Don't wait for the test results to start - consider them a convenient baseline...you can tweak the dosing once you get the results but if he hasn't been supplementing this is a safe option for him even without test results.
Stay strong. He is needs you even if he doesn't show it. My husband (secretly) likes me to bully him into doing the stuff that MUST be done (get O2 prescription, take the supplements), but he doesn't like talking about the headaches unless he initiates it.