Short answer: 45 minute drive is my max for a rehearsal. (For context: I'm a weekend warrior in a midwest city.)
Long answer: OP's questions strike me as permutations of "is it worth staying in band X or taking gig Y?" I'm fond of the three factors laid out by other forumites: (1) good tunes, (2) good hang, and (3) good pay. The higher a project registers on these three factors, the further I'm willing to drive. I'm involved in one project that rates low-to-medium on these scales but practices just 10 minutes from my house, so why not. I'm in another project that rates high on all three factors, and I make the 45 min drive for that one.