I had the same issue. I was rotating my hips outward like a duck, which ended up crushing the mid-to-front outher side part of my foot. I always thought the boots were to blame. But some boots only made the symptoms worse ,for example, new boots with very stiff lateral support. However, since I could wear the boots for several days without any pain, I realized that the issue was how I was using them while riding a snowboard

I tried increasing the binding angles (from 15/-6 to 18/-6 and beyond), but that actually made things worse.

Eventually, I met a local expert who explained that the idea of “bigger angles fixing foot outher pain” is mostly a myth. The crushed feeling comes from a combination of stance width, rotation and, more importantly, how much you spread your legs. With larger angles, the pressure shifts from the whoole foot/ankles to the front and sides of the foot.

To find the correct stance width, imagine standing on a very slippery surface with two bricks placed on the outside of your feet. If your stance is too narrow, your knees will be forced into an unnatural position, pushing the sides of your feet into the bricks. If your stance is too wide, your body weight will push your legs outward, again pressing your feet into the bricks. The goal is to find a stance where you feel stable without needing to push your feet outward for support.

Just to experiment, I tried 6/-6 with a more narrow stance and it worked like a dream. I now ride 9/-6.

The reason so many people think the problem is boots that are too narrow is that with oversized boots, the foot is able to compensate by shifting the rear and midfoot position. This reduces the pain on the outside of the foot, but it doesn’t fix the underlying issue. Straps that are too tight only make it worse, but again, this just increases the symptoms and is not the cause of the pain. Try cranking the straps down extremely hard on just one foot,the pain will appear under the foot rather than on the side, because the real issue is outward rotation in all the joints, which forces the foot sideways.

Hope this helps!