Chad, I have '05 Transits that did the same thing, size large. Soaked them for 3 weeks in hot water, shoved the barrels of 2 softball bats in them and the right one never loosened up enough. I called LF and they sent me XL overlays and toe pieces. Now that I put those on the large footbeds, they never hurt at all and I can cinch down the laces.
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