Worst headbanging pain ever was from a Wolfmother concert last winter. My neck was shot for half a week.

Also, if sunburns count, I had a pretty epic one at a water park a couple years back. I could not move my arms for two days without causing extreme pain everywhere. To top it all off, my family had a field day slapping me and whatnot. I got 5-starred at least 4 times in 2 hours.