Well I voted for Misery, cuz she really

ed him up in that movie, but a few others came to mind as I was reading your posts...
Candyman, the scene towards the end where the chick dives into the burning pile of garbage to save that kid, only to burn to death herself. I just can't think of a worse way to die.
Strangeland, anyone ever seen this movie? Dee Snyder is this whacko praying on kids off the internet. Anyway there's a scene in which he implies he's going to give this guy a prince albert... yeowch! They don't show that fortunately, but they do show him mutilating these girls up pretty bad, putting needles through them... everywhere. Really messed up movie.
Then there was Kolabus, I think that was the name, really messed up movie, basically every gets chopped up pretty bad in that film.
I'd also say American Beauty, for the scene in which Lester's wife and that real estate guy show up at the drive-thru window and Lester catches them cheating... not physically painful, but damn that'd tear your heart out.