Well...I purchased new insoles and WOW what a difference! My toes do not feel as cramped against the end of the boot now. They definitely touch and have a slight curl but its not as uncomfortable. The toe box in these boots is just very small and new insoles make it even more snug on all sides - which is fine and will likely pack out a bit.
Anyway, I'm keeping the boots and do plan to heat mold the intuition liners one more time - while wearing a toe cap.