Sounds like an aggravated pressure point from your shape of foot (photo). Find boots that fit, etc,etc, then get them heat molded, and maybe visit a great boot fitter. You have a protrusion that not everyone has, boot makers cannot account for that.
yup - i agree that it sounds like a pressure point.
the rulers are thus far the best fitting boots i've found, tried on a boatload at numerous shops. Rulers were the only ones i can go hours w/o pain, but eventually it hits.
Heat molded, etc - yes. At this point i'm thinking more along the lines of somehow extra heat molding and forcing the area in question out a bit extra... or what I noted in my 1st post in this thread...