Without going into the boring details as to why, after years of a particular issue I am considering surgery on my shoes in the form of removal of the upper where my left little toe tends to hit the side under certain conditions. I'm already using 4E's in what are approaching clown-length territory. It's not the shoes, its me.
I have definitely seen where people doing a thru hike have done such things as an emergency, temporary measure. I'm pondering doing this kind of thing as a for-the-life-of-the-shoe alteration. The general idea would be to remove the offending (smallish) part of the shoe and replace just that part with something more like a flexible membrane to keep out rocks and dust, but bowed out enough to remove most of the pressure when going steeply down hill. This is one of the (perhaps the only) things we have lost with giving up our leather boots.
Any recommendation? Has anyone done something similar?
One concern I have over the long haul is in not creating any sharp edges. I was thinking possibly using some form of microfleece glued on the inside and ripstop on the outside. I would be concerned with using some kind of glue/technique on the inside pieces that, again, would not create a too rough a surface. Waterproof-ness in not an issue – the more porous the better.

