Bingo! We may have a winner. My liners are wrapped with the inside flap ending to the outside of the boots.
These are Dalbello brand Intuition liners. When they were originally cooked and fitted by the shop I bought them from they heated the liners, buckled the boots (not too tight) and I stood on incline leaning into them while they cooled. This resulted in the liner squeezing up under the tongue in the gap running up the front of the bottom piece of the shell. The result was a square edged mohawk ridge up the entire front of the boot that stiffened them so they would barely flex.
After skiing them like that for a while I took them to another shop and had them recooked and went through the same fitting process again, but this time they put a piece of plastic inside the shell up the front that prevented the hot liner from pushing up through the gap. It definitely improved the flex, but still nowhere as sweet as with the original stock non-heat moldable tongue type lines, which had a much worse overall fit.
The liners have a black edging up the front on just one of the flaps, which I presumed went on top because of aesthetics, and to keep the edge from catching on the underside of the tongue, but apparently that is not correct. Unfortunately, I don't know which way the liner flaps were facing the last time the boots were cooked, but I'll switch them and see if it solves my problem, and how the fit feels, but I think there were probably fitted front to back as you say. Thanks for helping to solve my problems. With the flaps wrapped backwards one of the seams ran right up and around my ankle bone, which I could feel whenever I leaned into the boot.
P.S. After looking at the Intuition web site it shows the Power Wrap liners with the black edging on the outside, which means since my liners are right and left, if I use them like the picture then the inner liner flap will go to the outside edge, which is contrary to what you are saying.
Edited by mudfoot - 11/1/11 at 11:03am