Holy Moly Batman. You have some options here.
Tough Lights
1.
Streamlight ProPolymer 4AA Lux
Tough polymer body. Throw that is still very sufficient even though it is a Lux I. AA batteries. You can put lithium batteries in it for longevity in the trunk. Regulation is very good, 4 hours of runtime on NiMH. This light is does not produce a "wall of light", it is more for viewing at a distance, but it still has some usable spill. To reference, the older L2D CE with a Cree X-RE (not sure which one) had to be on turbo to max the lux produced from the ProPoly.
Price $28.95. BatteryJunction offers a discount to CPF members.
2. MagLite 2AA drop-in :
TerraLUX TLE-5EX Ministar2
The Mag series is well known about being tough. You can't have to put up some real effort to break one of these lights. The Ministar is brighter than the stock bulb/stock LED. According to BatteryJunction, the Ministar2 will increase battery life buy 2 hours. These drop-ins act somewhat like a regulated circuit. I believe (someone correct me if I am wrong) that when the LED hits a certain temperature the current to the LED is lessened to reduce damage. Even if the current is dropped this drop-in will be really bright. Carry it around for years, no problem. I don't know if you can put lithium AAs in the light. Made in USA. Price $24.95. BatteryJunction offers a discount to CPF members.
3.
Jetbeam C-LE v2.0
I use this light in the "tough" category because of its HAIII anodizing. You can throw it down, roll it in the dirt, and basically just beat it up and the finish is all good. Jetbeam seems to have stepped up their quality. This light is only a AA. It has more output than the Streamlight, just not as much throw. The Mag may have more throw. Regulation in this light is good with NiMH. I don't know if you can use lithium.
Price $29.95. This is with the BugOutGearUSA CPF discount.
Bright as Hell Lights
1.
Fenix L2D-CE Q5
This uses the Latest Cree Q5 emitter. This sucker puts out a lot of light. The body is a bit slippery compared to the C-LE. No knurling on the L2D. Some people have filled the outside with O-rings, or bike tire inner tubes. When this badboy is maxed out it produces a "wall of light". The turbo will have as much throw (if not more) as the ProPolymer, but it will also light up a good chunk of the woods right in front of you. This is not a "punch through the fog" light. Runtimes are crazy. Regulation is about as flat as you can get.
Price $62.50. Fenix-Store offers discounts to CPF members.
Fenix has a niche that other companies do not have. You can buy parts/bodies. You can purchase the L2D and then buy the L1D body later to "lego" a 1AA light, or you can purchase a P2D/P3D body to make a CR123 light. In the long run you could actually save money. Buy the bodies and you have 1 years worth of new lights. Cheaper to buy a body instead of a whole new light.
Unfortunately I only have 1 light in the bright category (and still in the $50 +/- range). There are a ton of lights available from
DealExtreme, I just know nothing about them. Maybe someone can pipe in with a few more models.