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Cutting Dalebello Shells

post #1 of 12
Thread Starter 

I have a pair of the original Krypton Pros.  I had them punched out to accommodate my protruding ankle bones, which solved the problem of the shell rubbing on my bone, but created a kink in the edge of the lower shell that is causing another problem. 


The gap up the front of the lower shells was originally straight on both sides, but because of the punch outs now has an irregular wave on one side.  I need to shave a little off the edge to straighten them back out.  What is the best way to do this?  File, drummel tool, or knife?   I know that the Krypts use a softer shell material than most boots.


Thanks, any insight would be appreciated.

post #2 of 12

can you heat them up, in that one spot, and just press it flat again?   is this a cosmetic thing, or a performance problem?

post #3 of 12
Thread Starter 

Pressing it flat isn't really a viable option because it will screw up the punch out.  The punch out created a ripple in the edge right next to it that digs into my ankle when I flex into the boot.  I just need to trim some of the irregular edge off.  Can I use a rasp file, my shark tooth p-tex base cutting file, an edge file, or is it easier with a carpet knife?.  I do not want to shred the edge, so I think some type of knife might work best.  I just thought one of you guys had some experience that might yield some useful tips.

post #4 of 12

shouldn't matter what the type of knife is so long as it is very sharp, i tend to use a shoemakers clicking knife(leather scalpel) to gut stuff like this as it has a hooked blade and is really sharp and strong, but i guess it depends what you have/can get hold of


grinding the plastic off is the other option as you can take a very small amount at a time and go round curves easier

post #5 of 12
Thread Starter 

Thanks everyone for your advice.  I ended up using a 4" panser file with large curved teeth that I got for cutting down and smoothing out p-tex repairs.  I was able to shave the edge of the shell down a little at a time and get it just right. Hopefully that'll solve my problem.  It is right where the seam on the Intuition liner rolls up and across the inside of ankle, which seems like a really stupid place to put a large seam on the inside of a liner. I may have to do something with that too.


Now that I am on the subject I can also say that I have not been particularly happy with the Dalebello Intuition liners that I purchased after-market.  The are definitely warmer and provide a snugger overall fit than the stock original liners, but they sure screwed up the flex of the boots. The shells were designed to work with a tongue type liner, and the Intuition wrap style that Dalebello uses (or at least used to use) were a pain to heat fit because they wanted to form a mohawk ridge on up the front, but even after hassling with extra plastic to reduce the ridging, they are still way stiffer and not as sweet flexing as with the stock liners.  I know that now Intuition makes tongue style liners, which hopefully is what Dalebello is using in their new boots.  The whole point of the 3-piece shell is a sweet progressive flex, which the wrap liners pretty much eliminated.

post #6 of 12

interesting point about the liners, never had a problem with them or any other overlap wrap liners in the way you describe.... were these moulded by a store or home moulded? the big seam that you talk about shouldn't affect the ankle... remember the inside of the liner flap goes to the inside edge of the leg, maybe i am reading you wrong, but it sounds as though they may have been moulded back to front

post #7 of 12
Thread Starter 



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
post #8 of 12

the liner in the picture is a left foot, lets get the description clear.....the medial side of the liner (inside) goes on the inside with the outer edge of the liner wrapping over the top of it.....if they were the other way round (the outside wrapped inside) then you would have the seem on the ankle bone, but if done correctly the seem will be on the outside (away from the foot, close to the shell, rather than on the lateral side of the boot) and there should be no problem from that seem...... 


the inner flap WILL end on the outside of the boot (lateral rather than closest to the shell) but that should not cause a problem at the medial ankle


hope that clears it up, confusing myself now..... unless of course the stretch you have had done for a protruding ankle bone was for the lateral ankle rather than the medial

post #9 of 12
Thread Starter 



Thanks again.  I think I understand the wrap correctly now.  To be clear, the problem I am experiencing is not with the edge of the inside wrap, but with a seam in the liner that curves up just behind the protruding ankle bone on the inside of my foot.  The seam's position remains unchanged regardless of which way the liner is wrapped.  It is right where you pressure the liner and shell when you lean in and flex the boot for a turn.  The fit of my boot is such that I use thin socks, which results in the liner seam aggravating my ankle on both feet.  I will try and have the liner punched out in that area, or maybe cover it with tape, but it just seems like the liner could have been better designed in that respect.


FYI:  In order to check out the wrap issue I went to the local Full Tilt dealer,  It was interesting to note that their display models had some of the Intuition Power Wrap  liners wrapped with the inside flap facing out, and some facing in.  I assume they came from the factory that way.


I really appreciate you taking the time to help me.  MF



post #10 of 12

ah, ok the seam that goes form where the liner is silver to where it is black......not had a problem with that in the past..has it been overheated when moulded to make it go crispy?, normally the seams are pretty flat/soft on the liners

post #11 of 12
Thread Starter 


Originally Posted by CEM View Post

ah, ok the seam that goes form where the liner is silver to where it is black......not had a problem with that in the past..has it been overheated when moulded to make it go crispy?, normally the seams are pretty flat/soft on the liners


It is probably a combination of things including the seam getting a little crispy from being reheated, the punch out of both the upper and lower shell in that area, and my weird feet bones. The big protrusion on the inside of my foot (talus?) is higher and farther forward than normal, so it is right where you apply pressure to the boot when turning.  Unfortunately, I like 3-piece shell boots, but my problem is in an area that falls right at the junction of all three pieces of the shell.  It requires a punch out of the upper and lower shell, and a C-shaped pad on the liner around the punch out area.  The seam in question rubs on my tendons right above the bone and leads to radiated pain up my ankle.  If I jack the shell far enough to stop it rubbing on my ankle bone it distorts things to the point of causing other problems. I will not bore you any further with my medical issues, but I appreciate your help and the benefit of your boot knowledge. 


All things considered, it still seems like a stupid place to put a seam on the inside of the liner.

post #12 of 12

We buy shell only and use our own Palau Liners.NH12:3.JPG

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