Drove the 40 miles back to Pelican Ski after work with the ski boots (and ski socks), here is what transpired:
* I was originally fitted last year in the Salomon boots by the store's head/lead boot fitter. He was not working that evening therefore worked with another boot fitter (older gentleman) who has been fitting boots for over 25+ years.
* The boot fitter tonight took one look of me and assessed my height, weight, build, skiing style etc.. the moment I said "hi". Apparently I fit some type of demographic he is use to. Basically he cited back my numbers without ever asking or measuring me - caught me off guard and was 100% accurate.
* 1st thing he did was listen to my entire store (outlined above) without saying a word.
* 2nd thing he did was direct me to put my boots on while he quietly watched me.
* 3rd thing he did was remove the liners, placed my foot in the empty shell (toe first up front, then heal against the back). Took a very small flashlight and looked all around inside the shell.
* 4th thing he inspected the liner with my foot in it.
* Boots and liners in good condition
* I am in the proper flex boot.
* Heel wedges (raisers) needed/required to: 1) correct my stance; 2) address how the boot cuff sits on my leg.
* User error: I am buckling the boots incorrectly, by making the bottom buckles on the foot too tight, and the leg (calf) buckles too loose. He wants me to latch the foot buckles with very little tension and tighter on the calf's than I have been setting them. The good news is I am buckling the buckles in the correct order.
* When I explained and emphasized I didn't have an issue till now and when I did loosen the front (foot) buckles I had foot movement, he was surprised to the point more like shocked. To paraphrase his comments (for some humor), those boots fit me better than OJ's glove. All fun aside, they are a complete perfect fit therefore he was baffled at how I could make the comment they become loose fitting if I loosely clamp the 2 front buckles. So he inserted a very thin footbed riser underneath my custom footbed to raise my foot up thinking my foot sunk too far down (compression) leading to the shell incorrectly locking my foot into place.
He concluded with not wanting to make too many changes at once in case of missing something or making things worse especially since the boots appear to fit me extremely well.
Let's see if those 2 changes solves the problem, stay tuned.