I can relate. I made so much progress with my hyperacusis that I became a bit too self-confident, thinking I can use headphones again. I could even use my tinnitus maskers that I did not tolerate in the worst period of my hyperacusis and walk outside a bit without my earplugs so I was thinking I am making a recovery of my hyperacusis. At first I only used the smallest volume of my headphones that I could tolerate for short periods of time (without issues) but then I decided to up the volume a bit. Only a bit. Then last week after listening to music using headphones I got listening fatigue, my reactive tinnitus exploded and I have had a tinnitus/hyperacusis spike since then. I again feel a burning sensation in my right ear and I feel like I am going insane without constant masking of my tinnitus. So it was not worth it. Maybe I would have tolerated the lowest volume but even that is probably not worth the risk of worsening my hyperacusis.
I find it difficult to accept I can´t use headphones because music sounds so much better using headphones. On the other hand, I accept it because I have made so much progress and I can definitely live my life without using headphones.