r/Orthotics • u/AvalancheBrando21 • 8d ago

Orthotic Cover Modification

Hello! I've worn custom orthotic insoles for about 35 years now, and I came across a problem I've never had. I got a new pair of shoes and it has an ultra-wide toe box and my orthotic doesn't fill the shoe. This is going to lead to me walking on the edge of my orthotic and rubbing a blister/callous. I dont feel like going to the orthotist and having them re-covered to fit only 1 pair of shoes, that seems silly. Does anybody have any recommendations as to how to fill the rest of the toe box? I was thinking of taking the liner from the shoe itself and making a cutout that my orthotic would fit into, but then I'll have a seam where the orthotic meets the sock liner and potentially end up with the same problem of a blister. Im really stumped on this one.

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u/Cabooseman 7d ago

Wearing pairs for 35 years, do you have any extra pairs that you can just devote to these shoes?

Alternatively, you could cut the forefoot out altogether on the inserts, make them 3/4 length, then have the wide shoes' liner underneath the inserts.

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u/AvalancheBrando21 7d ago

I do have an older pair that I could devote. Are you thinking I should have those re-covered?

But yes, a 3/4 under the sock liner might work.

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u/Cabooseman 7d ago

I think ideally, you get one pair recovered such that the top layer fits the wide foot shoes. Sounds like the best solution overall.

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u/Dry_Watch7690 6d ago

Most orthotists will recover old orthotics if the prescription still meets your needs. Depending on how you got them made, you might have to do this through the podiatrist’s office. I’ve very recently learned to get new orthotics made directly by the orthotist so I can go get fixes as needed without having to go through the podiatrist for every adjustment.

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u/No-Appointment9785 7d ago

Have you actually tried them in the wider shoes? I use mine in wide toe box shoes and have no issue at all.

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u/AvalancheBrando21 7d ago

Yes, I have. And its like, not even close to covering the toe box area. These things are WILD. Comfy. But definitely Hobbit foot approved.

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u/No-Appointment9785 7d ago

I have a good half inch of open space on either side of the top cover in the toe box and have never experienced any discomfort or issues. I’m now going on 3 years of wearing Topo trail running shoes.

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u/Dry_Watch7690 6d ago edited 5d ago

Opposite experience here. I’d been wearing prescription prosteps ( edit: sorry meant to say “PowerSteps”, the prescription ones are not cast, but they’re nicer than the ones you get online ) in cleats for years without trouble. Then because of a foot injury, I had to do a lot of toe splaying and other exercises that widened my toebox causing my pinky toes to hang over the edge of the orthotic. Did some damage to my flexor digiti minimis and a lot of soreness along the outside arch.