How to Fix Sixth Toe Pain in Ski Boots
That sharp pain on the outside of your foot, right behind the little toe, is one of the most common ski boot problems, and one of the easiest to fix. It's a bony bump called a sixth toe hitting the shell, and a small, targeted punch makes it go away.
What is a sixth toe?
A sixth toe, also called a tailor's bunion, is a bony bump on the outside of the foot where the little toe meets the foot (the head of the fifth metatarsal). Ski boot shells are narrow and stiff right there, so the bump presses into the plastic every time you flex forward or roll onto your outside edge.
It's different from a regular bunion, which is on the inside of the foot at the big toe. The fix is the same idea though: add a few millimeters of room in the shell exactly where the bone hits.
Signs it's your shell, not your liner
- You can point to one spot with a fingertip.
- It gets worse the longer you ski, and sharper when you flex forward.
- Loosening the first two buckles helps a little but doesn't make it go away.
- With the liner out, you can feel the bump touch the inside of the shell.
How to punch for a sixth toe, step by step
- Find the exact spot. Take the liner out and wear it on its own. Press along the inside of the empty shell with a fingertip, or put the liner back in and flex forward, until you find the spot where the outside of your forefoot hits. Mark it on the liner with chalk.
- Transfer the mark to the shell. Put the marked liner back in the shell and pull it out again. The chalk leaves a mark on the inside of the shell. Mark the same spot on the outside so you can line up the punch.
- Heat the spot evenly. Hold a heat gun 3 to 6 inches from the shell and move it in slow circles around the mark until the plastic is warm to the touch and just slightly softer. Don't heat until it looks glossy or smells.
- Punch with a small head. Set up the clamp with the Small punch head inside the shell on your mark and the receiver outside. Tighten slowly. Aim for about 3 mm on your first punch.
- Let it cool under the clamp. Leave the clamp tight until the shell is completely cold, usually 20 to 30 minutes at room temperature. Taking it off early lets the plastic spring back.
- Test and repeat if needed. Put the liner back in, buckle up and flex forward a few times. If you still feel it, do another small punch in the same spot.
Go small. 3 mm feels like a lot inside a ski boot. You can always punch again, but you can't easily undo a punch that's too big.
What you need
- A heat gun (a strong hair dryer can work on thinner shells)
- Chalk for marking
- A boot punch with a small head. The BootForge Pro kit has the Small, Medium and Large heads, or you can add just the Small head to a kit you already own.
For the full process with photos and video, see How to Punch Ski Boots.
FAQ
What's the difference between a sixth toe and a bunion?
A bunion is on the inside of the foot at the big toe joint. A sixth toe, also called a tailor's bunion, is on the outside of the foot at the base of the little toe. Both are bony bumps that press on a ski boot shell, just on opposite sides.
How much do I need to punch for a sixth toe?
Usually 3 to 6 mm. Start with about 3 mm, ski it, and add more in a second session only if you need to.
Which BootForge head is best for a sixth toe?
The Small (20 mm) head. It puts the room right over the bump without widening the whole forefoot. If the whole outside of your foot is tight, the Large (40 mm) head spreads the room over a wider area.
Could it be the liner instead of the shell?
Sometimes. If the pain is a general squeeze rather than one spot, try loosening the first two buckles and check your socks and footbed first. Heat-molding the liner can also help. If the pain continues, see a podiatrist or a boot fitter.