So I made my own boot punch for under $30. I hope this helps some of you do-it-yourselfers with sore feet.
You will need:
round door knob ($1 at goodwill)
2" plumbing end cap ($.87 at Home Depot)
Irwin part number 18sp, 18" long locking c-clamp with swivel pads ($24 from Industrial Supply)
Remove the swivel feet on the clamp by grinding off the head of the rivet and punching it out using a punch or nail.
Cut off the end of the doorknob as shown in the picture. I used a hacksaw.
Drill a 3/16" hole through the center of the doorknob and counterbore one side.
Cut a 10-32 flat head bolt so that when you insert it through the doorknob, it's flush with the outside.
I used washers and a nut to center and attach the doorknob to the clamp as shown below.
To attach the cup to the clamp, drill a 4mm hole through the center of the cup and through the center of one of the swivel feet that you removed earlier. Counterbore the swivel foot from the top. I used an M4 x 20mm bolt to attach the swivel foot to the cup (see below). Then use a 3/4" long 10-32 bolt to attach the swivel foot/cup to the clamp.
I also made a smaller ball and cup using a golf ball and a 1-1/2" pipe end cap. I put the slice in the golfball using a Dremel tool.
And that's it. I used this punch to make more room for the balls of my ankles and to widen out the toe boxes of my Dalbello Krypton Pro ID's. I've taken my boots to the "professionals" before but they have never come close to the comfort level I have achieved with this gadget.
A couple of tips: To figure out where you need to punch, tap on the outside of the boot until you feel tapping overtop of the problem area. Another method is to remove your boot liner, put your footbed in the shell and stand in the boot. Reach inside the boot and try to mark where your problem areas are.
Hold the heat gun about 8-10 inches away from your boots on the low setting and heat until the boot is too hot to touch on the inside (make sure to remove liners and footbeds). I found it helps to heat the doorknob end of the clamp in boiling water before punching, otherwise the cold metal cools the plastic off too fast. When you have the punch just where you want it run the whole setup under cold water in the sink to set the punch. If you don't have a heat gun, you can heat your boots up in boiling water too. The downside to this method is that you will have to heat a larger area than you want to work on, which risks undoing previous boot punches you've done.
To do a longer punch area like the side of the toebox, just work the clamp back and forth along the area you need to widen. When you have achieved the right shape, run it under cold water to set it.
I have thermoform liners and I have found that heating the doorknob end of the clamp in boiling water, doing a light liner punch, and letting the whole setup cool works well for light problem areas.
Punches can be undone by reheating the area.
Good luck and happy bootpunching.