Okay how do I stop this from happening to the top of my foot? My boots are always crushing the big vein on my foot. It's been a problem for the last few seasons, especially since I've been fitting into a smaller boots. It really ruins my day as my feet go to sleep. All the "boot fitters" just try to sell me a boot the same as my shoe size... this elevates the problem, but the boots don't last with all the riding that I do.
Silly question 1: have you tried different manufacturers?
I have slightly high arches and high insteps so the fit on my instep is one of my priorities for boots. I had the "pleasure" of trying and buying new boots this year. I really didn't get on with Burtons for example. The tongues seemed to be a bit stiffer and pre-curved and designed to push your foot down when you push your shins forward. A nice idea for counteracting heel-lift but very uncomfortable for me. I couldn't even get my foot past the tongue of some adidas sambas.
I think I tried some lace-up 32s which were more comfortable. In the end I went with some Salomon Dialogues which I'm very happy with.
There wasn't much selection this year so I didn't try enough to give any definitive recommendations sorry.
Silly question 2: can you tighten the top and bottom of the boot separately?
My last boots were laced and had a "lace-lock" between the lower and upper sets of eyelets. My current boots have 2 zone speed laces. Being able to leave the lower section looser than the top section makes a big difference.
I also tend to think that laces can be slightly more comfortable than speed-laces or boa (saying that I love the convenience of my speedlaces)
Similarly, don't over-tighten the liners. There's a fine line between just-firm-enough and pain at the end of the first run.
I haven't got to the point where I needed to cut material away. I know you said you tried this already but there is good thread on this topic somewhere on this forum where it worked well. I think the user was
@neni ?
I think there is also an angrysnowboarder video about this where he uses foam-padding to help make a "bridge" over the sensitive area.
Hopefully you can avoid sizing up as this will end up creating new issues. Good luck!