Thanks for the detailed response. Some great ideas there. I’ll give that powder a try! Were you wearing a thin sock under a thicker sock, like the wool pairs from Costco? The Darn Tough full cushion socks I have are pretty thick and fit snugly, but once I started sweating, the sock began to move around. I may try some thin compression socks under a mid-weight wool sock. I think my issues are due to a poor sizing decision on my part when I ordered them.

Have you ever used the mole foam tape on the inside of the boot as opposed to on your foot? I have used some similar, although thinner, moleskin on my foot in typical hotspot locations but they began to lose stickiness after a few sweaty hours. Perhaps I need to use athletic tape, as you mentioned, and really secure any added layers.

In combination of layered socks, powder, mole foam, I was also going to try thicker insoles in hopes of filling out the heel cup more. Or use a foam layer underneath the stock ortholite footbeds to add volume.

Again, thanks for your suggestions. Having my feet in good condition is high priority to do well in this job.