“I still struggle to find shoes that truly fit me well and are trail worthy.
“(I very likely did too much too fast, but my foray into minimal,…
Put two statements from your post up above to show the contrast between “struggle” and “too much too fast.” There may be a contradiction there. And you may be focusing overly on a scientific approach where only trial and error will work.
Except for a few custom boot makers, most of whom may have retired, there is no science about fitting hiking footwear. What works for one person, many not work for many others. So what can a hiker do? Will share what I did, and maybe it will help.
Back when trekking every chance I got, my feet just started to hurt. There were all kinds of hurts, so won’t try to analyze them. But the future looked grim.
First, I happened to meet a lady at a bar at a concert who told me about a fantastic podiatrist who helped her to walk comfortably again. It may be significant that this came by word of mouth, because every other podiatrist I saw was not at all helpful. The one she recommended made me orthotics, or footbeds, for street shoes, and later for hiking shoes. The hiking ones were carbon fiber, a brand called PAL, that were more flexible. These footbeds were similar to the ones like Superfeet seen in the stores, and that come in several different types, but are not custom designed for your feet. So, to the extent that science is involved, it came from the one podiatrist who studied and worked for many years to master his craft. Most important, my street shoes were suddenly comfortable with the footbeds, and that provided some assurance that the doctor knew what he was doing. I have a woman PCP, but for fitting a man’s foot, I prefer a male podiatrist.
Next, I visited numerous large outdoor stores, like EMS, REI, and a some similar stores that do business from just one location, like Farmway in Bradford VT, Kittery Trading Post in Kittery Maine, and the camping JAX store in Fort Collins Colorado. They were chosen because they carried numerous different models of hiking shoes, and had plenty of sizes in stock. At each such store, I tried on shoes first out of the box to see if they were comfortable walking around for a while. If so, would try them on with the custom footbeds, and compare. If the custom footbeds improved the comfort, I’d go back another day and try the shoe on again, because feet change. It was a problem being constantly interrupted by salespeople (guys, mostly), but would explain why it would take a few hours to shoe shop, and after a while, they’d let me focus on the task. Some stores have ramps that are indispensable for trying on hiking shoes.
Finally, I’d purchase a pair and wear them at home for longer periods, maybe an hour when doing housework or making meals, etc. Aside from comfort, the focus was also on whether the shoe held the heel solidly, without slipping upwards or sideways. And whether the toe box did not impinge on the toes, either from the sides or from the top. And whether they pressed to hard on the front of the foot when laced up. If they did not remain comfortable, or did not pass the above tests, they went right back for the refund promised by the salesperson so long as they’d not been worn outside.
This process went on for several years until I settled on shoes to take dayhiking. If they were not up to task, they were set aside to be sold on consignment, and the hunt went on. Wouldn’t call this a “struggle,” but a long systematic process, requiring a lot of patience. Have made mistakes along the way, like the time a day into a week backpack, when it dawned that what I thought fit perfectly for day hiking, pinched the toes after a day wearing a pack, to the extent of causing inflammation and infection.
Drained the infection, rubbed crushed iodine water pills into it, wrapped up the big and second toes with colloid bandages, and was able to go on without pain. But most of the time, nothing bad happened. Note that I use watershoes to otherwise keep the feet dry (a little extra work), and do not get blisters on the heels or soles with shoes that fit well.
After a few years, found that there were certain brands that tended to fit me, and focused on those. Tried some models of Superfeet on those, and found one model of shoe that worked. The rest worked better with the doctor’s footbeds. So now I know exactly what models and brands to use when the old ones wear out; so there was a big pay-off from all the time spent. This has been a long post, but so was the process. Good luck to you.