I got a bargain on a pair of Scarpa-branded Intuition overlap liners to replace the packed-out liners in my late 1990s Lange XZero9 shells (hey, the budget is tight, and the shells are in excellent condition). I had them molded at my reputable local shop, and the results are close to perfect, but I do lack toe room. My impression is that these liners (for the T-Race Scarpa tele boot, mondo 30) are just slightly too large for the 334 mm shells (Lange nominal US 11-11.5). The cold liners were a very tight fit but did settle into the shells with only slight bulging near the heel, and the new Footbalance footbeds and hot liners went in (with some effort) during the molding process. The shop wanted to do the first mold without the toe caps to ensure that the liners fully seated in the shells, and that seemed to work (with cotton balls between my toes) fine (aside from my pinkies hurting like hell at first).
I skied on them the first time yesterday, and the overall fit and performance are awesome. Great foot-to-shell connection but kind of cushy feeling, powerful-firm with an extra 2" power strap around spoiler and liner cuff, but forgiving and plush with just the wimpy Lange power strap. But my toes are jammed in pretty tight. Our intention was to mold again after trying them out, this time with the caps, but I wonder if we also need to relieve a bit of volume in the shell, either (carefully) with a plug grinder at heel and toe or by ballooning the toe box out a bit (top and sides) to allow a bit more space for my toes. There is a clear impression of the Lange toe dam/seal on the top of the liner, so I think some vertical space might be enough by itself.
Will the Ultralon foam compress further with the toe caps, and can we heat just the toes, since the general fit is excellent?
Another thought was to heat just the toes outside the shells and hyper-compress the foam there to reduce volume, but I'm afraid that might diminish the Intuition warm-toes effect.
I really think a 29.5 liner would have been perfect, but the results so far seem to indicate that just a bit more volume is needed, and only at the toes. My shop molds by having you stand in a skiing position while cooling rather than toes on a 2x4, so I also wonder if we might get a bit more compression in the heel pocket by doing it that way the second time.
I read a thread here from last year about the opposite problem of a too-big shell and wondered what anyone might have to offer about this situation. It's a very good fit as-is, but those toes are mighty tight!