For brightness in a small package, you almost always want lithium, or at least rechargeables. Are you really against using lithiums? CR123A batteries are fairly inexpensive online, at about $1 each. When you go looking for high-end lights, lithium cells will almost always be used. If you want to keep cost down and really hate the idea of lithiums but want a high output light, consider a rechargeable, such as the Inova T1, or a Surefire L7.
Right now, the best LEDs can't match the best output of incandescents, but in a small form factor you can find some very bright LED-based lights.
If you do really want to use alkaline batteries, I would recommend the Streamlight 4AA Luxeon, a favorite of many CPFers because it is fairly inexpensive (~$40), bright, and uses common batteries. It is plastic, and I don't know how "solid" it feels, though, as I have yet to own one.
Another good option would be a Fenix L1P or L2P. Although they are not exceptionally bright (by CPF standards), they are much brighter than a Mini Maglite and also top the output of a 2D Maglite (unless I'm confused). The Fenixes have a really nice solid feel to them, and the L1P is impressively small. They use 1 and 2 AA batteries, respectively. CPFer foursevens sells them here --
http://fenix-store.com
I'd also recommend a Surefire L2 or L4, if you're willing to use lithium batteries. You can get either for about $140 with the member discount at OpticsHQ. My new Surefire A2 (hybrid incandescent and LED) is the only metal-bodied SF I've had experience with, and the build quality is absolutely fantastic. By the way, the low output (15 lumen) mode of the L2 should be fine for most tasks, but you always have a "turbo" high mode handy (100 lumens for about 30 minutes).