Originally Posted by
weasel1
Baking will likely solve the issue. If it is still annoying post-bake, then take a hair dryer to the tops of the liners (carefully!!!) while they are on your feet, and slowly work them away from your leg at the top until they give you some more space. Or wrap your calf at the top with some extra cloth when you first mold them.
Most likely, though, they will be fine once baked.
Oh, and use a footbed. As you may have noticed, I like the ALINE footbed, especially in this application. Put the footbed UNDER the liner when you mold them. Just make sure it is in the right place in the shell (all the way back against the heel...tape helps) and to stomp flat down hard a few times once they are on and molding to get the liner to conform nicely to the footbed. Doing this is nice for two reasons: 1). It keeps the footbed on a firm, stable platform (the bootboard) instead of a soft, squishy one (the bottom of the liner) and 2) it is much nicer and warmer against your foot.
The ALINE is (annoyingly) grippy, and so can make sliding into the boot tricky when inside the liner instead of under it. This is a point of contention between the designer and several of us who worked with this product from its initial release, as is putting it under the liner. All I can say is, everyone I know of (including me) who has done this has liked the result...a LOT.
[/bully pulpit]
P.S.- If you are in VT, and fancy a trip to Middlebury, I would be happy to help fit you. No longer work in a shop, but with some creativity can accomplish almost all of the same things in the kitchen....mostly.