My Zipfit Experience (verbose edition)
I asked Foot Dynamics in early December to try and get me some Zipfit plug leather liners for my Kryptons, but got no action out of them before my first trip to Utah in mid-January.
So I went to Superior Sports at Snowbird and got fitted with plug leather liners. They initially felt good but after skiing them for a full powder day I was bottoming out my buckles and longing for some more padding. So I took them back the next day and the fitter was considering injecting more molding compound in the tongue and around the ankles when we realized that the slits in the leather were missing to access the ankle injection ports. So they exchanged the plug leather liners for some new Expresso Neoplush liners (since they didn't have any Expresso Leather liners in stock). The Expresso's extra molding material and thicker neoprene forefoot work great with my "Comfort" shell fit. The plug leather liners probably would have worked well in my old size 27.5 Flexons which were closer to a "Race" fit for my skinny low volume foot.
When I switched to 27.5 Kryptons last season I got some extra heel volume, instep height and shell length which I didn't need (and 26.5 Krypton shells had only 1/8" gap behind my heel). The Intuition liners I put in my Krypton's last season took up the volume fairly well, but the firm foam wasn't particularly comfortable when I clamped down on the buckles for maximum control. Also, the liner height barely reached the top of the tongue and rear spoiler (in the raised position). The Zipfit's tongue height is about the same as the Intuition, but the Zipfit cuff is about 5/8" taller than the spoiler.
The neoprene lining in the Expressos is plush and comfortable, even when buckled tight. It's probably not as grippy as damp leather but grippy enough considering the glove fit. The molding compound forms such a deep achilles channel and heel pocket that it becomes difficult to get get your heel over the hump while sliding your foot into the boot. If you force your foot into a cold boot you can smear some of the molding compound and lessen the fit. If you force your foot into a warm boot you will displace even more molding compound but hopefully you can partially reform it by pumping the heel and liner up and down several times per Zipfit's fitting instructions. To completely reform the liner it needs to be hot (preferably along with a hot shell).
I tried inserting and removing the Zipfits from the shells while attached to my feet, but the forces are high which can cause excess wear and tear. The first time I ripped a flap in the outer neoprene in the forefoot under the screw that holds the tongue retainer strap (which I have since removed for better access). Also, the rubber sole started peeling back at the heel. I repaired both the rip and the flap effectively with Aquaseal. My next insertion scheme will be to do douse the shell interior with silicon spray before trying to insert my foot and liner together, but then remove my foot while leaving the liner in the shell.
The current batch of Zipfit liners appear to have some minor quality problems, which is dissapointing with ~$330 liner. In addition to the missing slits on my first Zipfits, both pairs of liners had the velcro toe flap sewn through which eliminates the adjustability feature. Also the plastic eyelets which anchor the lacing system pulled loose on one of my liners due to bad sewing.
Overall I am happy with the Zipfits due to their oustanding comfort and performance. Most days I use a heated boot bag ( http://www.mountainmiser.com/product...l.cfm?PID=1784
to warm the liners and shells for a couple hours before skiing. If leave the bag plugged in overnight it gets the liners almost hot enough for a complete refit.