Ill start with a bit of history. I'd say that out of every thousand people that ski probably 2-3 have problem feet like I do. I've been through 4 boots over the years (ski + snowboard) and on top of that I'm an internet nerd, I research my bootfitters. I have never had a non-painful day on the slopes and ski around 80 days a year but I think I'm getting close.
Current situation is this.
Wearing 2012 Lange RX130's, custom footbeds and forefoot width shell punches done at Fanatyco, Whistler. First day out had the familiar agony under the front of my arch, stopped every 100 metres or so for the rest of my limited day to pretty much die. After this I went to see a bootfitter in Revelstoke that was recommended to me. He gets me to flex forward and watches my arches collapse inwards. Tells me there is way too much arch support built into my footbeds and grinds the yellow support part down to basically nothing (instaprints). Get back in the boots, pain goes from unmanageable to "dull but doable".
Unfortunately, my other problem is freezing feet, and I've never had an issue as bad as I did with these boots. They seem to let in quite a bit of snow/water, as well as having a super thin liner with a neoprene toe cover. Frostbite ensued. I was then instructed by my doctor to get hotronics, tried them for a few days and while they fixed my cold toes problem, my toes still got wet and I hated having the hotronics installed. I thought back to my snowboard boots (Ride Insano BOA)...."hmmm, my feet weren't that cold with Intuitions". So down to Valhalla Pure Outfitters I go to get some mondo 30 Luxury Liners (medium volume). Put the liners into my shells to make sure they fit (29.5), they did. Go back to my bootfitter and put in the new liners, mould them while in the shell and buckled up. Unfortunately, since the liner is higher volume than the Lange one, I have a whole new world of pain width-wise around the middle of my foot and just in front of the ankle that I only notice when i start skiing. The kind of pain that makes you stop and take your boots off on a 40 degree pitch. So my questions are:
1. The footbed is in my liner and taking up a it of room, should I try getting them remoulded without a footbed and just my foot? It seems that most of my pains come from lack of room or support my foot does not want. Is no footbed at all a no-no?
2. If I get the shell punched to accomodate for this new width problem, will an intuition liner eventually work its way into the new found space or will I have to get them remoulded in my modified boots? Should I punch them at all considering the liner could just pack out even though I had no pain in that area with my previous (thinner) liner?