There is NOTHING wrong with your feet. It sounds like the custom fitting isn't correct. It should have addressed a too-long big toe. But - before we all panic: Unlace them down to the toe. Put your feet in. Start lacing up. Pull it as TIGHT AS YOU CAN on each lace cross - or get your husband to pull them. You should feel the toe of the skate lifting up and away.
I tried that. It helped, but not nearly enough. The skates feel like they're at least a half size too short. I wouldn't mind if my toe brushed against the front, but it is violently shoved against the front of the boot. It feels like it's bruising my toe.
IF that doesn't do it, then, complain. Custom skates should fit all of the quirks and oddities of your feet. You could try to get it punched or stretched, but, why should you? They're custom ! they should fit! (plus, it's hard to get toes punched out).
I think the bunion problems will ease with time. On my second wearing, they're already less pronounced. It's the too-short length that's got me worried.
Do not worry- when you stand, your balance is not the same as when you skate. When you bend your knees, the heel will sink further back and the toes will retreat.
I think Harlicks are really cut to the foot shape. My Riedells had room in the toes (even though my measurements were correct) and that drove me crazy when I bent my knees. With the custom Harlicks I can feel the toe barely brushing up against the front when I skate, but it really pushes into it when I just stand with straight knees. Make sure you BEND, BEND , BEND your knees when you skate.
I haven't worn them on the ice, but I have mimicked a skater's stance at home, and it's still bad when I bend my knees, unfortunately. The left boot isn't quite as bad, but with the right boot, I'm scrunching my toes to avoid serious pain. If it was just a matter of the toe "brushing" the front, I'd be fine, but it feels as if the boot is at least a quarter inch too short.
Harlicks are heat moldable - is there anyone local who can do that for you? It may help with some of the issues, provided that whomever is doing the molding knows what they're doing beyond simply heating them up and lacing them up (that alone would help, but a good heat molder has a few tricks they can do to make them even better). I second Sk8tmum's advice to pull UP on the lace crosses (not tightening the laces, just pulling up on the lace crosses over the toe box area) to see if that will help give you a little more space in the toe box.
There is nobody local who does heat-molding, as far as I know. We have one pro-shop, but the owner himself admits he's clueless about the business. They use an automatic machine to sharpen skates, and they sell a lot of hockey equipment. That's about it. As far as tightening the laces, I used a lace hook when I laced them, so they got pretty snug. In fact, my right foot went to sleep after about 10 minutes. Didn't help much. I think I did it the way you suggested, but I'm not entirely sure. I pulled up at the crosses, but it tightened them when I did that.
You mention that you tapped your heel back, but you may have to do it MUCH harder to really seat your heel - if your heel isn't back all the way your toes will end up crunched up. Also, an obvious thing, make sure your toenails are trimmed short - especially on the big toe.
I tapped my heel hard enough to jar the guards loose. It was about as hard as I usually do it. I've got my nails trimmed as short as I dare, if I go any shorter, I end up with ingrown nails. I'll risk it and try cutting them shorter anyway, but quite honestly, I don't think that will buy me more than 1/16" and it feels like the boots are at least 1/8" to 1/4" too short. But perhaps it's an illusion, perhaps they're just a hair too short, and it just feels much worse.
I think I may have identified at least part of the problem. The toe box is too shallow. If I squeeze from the sides, making the toe area taller, the pain eases tremendously. Of course, then they're too narrow, but at least it's a clue. Is there a way to stretch them vertically, to make the toes taller? The guy who fit me said that my feet were very thick, and he measured around my ball, arch, heel, and ankle, but he didn't measure around my toes, so that could be part of what's happening here. I do feel like they're too short, as well, but that might be bearable if we can find a way to stretch the height of the toe box. Any ideas?
I just wore them for perhaps 10 minutes, and 5 minutes later, my toes are still feeling bruised. It's definitely something that needs attention. I'm loathe to ship them back to Harlick, though, because who knows how long they'll take to fix them? Or if they even
can fix them? I'll do what needs to be done, of course, but I'd like to try and fix them myself, first.
Other than the toe problem (and the bunion problem, which is already starting to ease) the skates are pretty comfortable. I love the heel lock and all the padding. The ankles are fine, no problem there. They're great, except for being too short and too shallow at the big toe.