Dubya tee eff, ski boots are t3h suck.

look at lange

Take a trip to a big resort next winter and go to a good shop. I have FAR more problems in snowboard boots than ski boots.

There is such a thing as a warm, comfortable ski boot.  It's called an AT boot.  Unfortunately they kind of suck in-bounds, so I'll have to agree with your statement.  I've done about 4 hours of boot fitting on my FR120's and even though they fit just about perfect I still have to unbuckle them every run (or ski with them loose, but that would be no good).

Cut off your feet and get fake one's?

If you can explain the problems you have had in each of the boots that would help get an idea of what ur looking at in terms of a new boot.

ie; pressure on your anke, ball of foot pain, cold feet, numb feet, toe bang, too much heel lift, pressure on your instep etc.

If the problem is volume, with an AA width foot you may want to look into a Foam injection liner, custom footbed and a narrow ass boot. Next year Lange have some 92mm lasted boots, which may or may not work for you with a foam liner. You really need to find a decent bootfitter as AA width is outside of the norm and you probably require more attention than someone with a C width foot. If you have a lot of pronation ie your foot collapses significantly when flexing forward, you must get a custom footbed. In cases of severe pronation, your feet can elongate by a whole size, meaning your getting a sloppy fit when that pronation is neutralized.

Unfortunately your gonna have to dig into those pockets of yours to get the right fit. LIners, footbeds, shell customisation all costs money but its worth getting done as long as its done right. For instance if you get a foam liner, make sure the store (this goes for footbeds too) sells alot of them as they are easy to fuck up and it would then be a waste of money.

IMO its just finding the right fitting boot and then spending a couple hours in the shop getting them perfectly fit to your feet.

SPK's fit my feet great to begin with, with some liners and some other shit done to them they feel like shoes when I'm riding.

The post purchase boot fitting is when boots really come into their own, then once you break them in they should be comfy if you got the right boots.

Sorry, been working like 11+ hours a day these past few days....tired.

Haha, which of these don't I have is more like it.
The pronating causes ankle contact and (usually) pain in most boots on the inside of the foot.
I have a very narrow heel, so lift is a problem in every boot I've tried, significantly, and I've never really had it corrected because what time I'm not in school or working, I want to spend riding if possible. Toe-bang too, usually when trying tail presses and butters.
However, because of the collapsing of most of my arch when weighted (relating to the pronation), my forefoot "splays" out, and is a fair amount wider than my heel, so usually around my 4th toe contacts the shell of the boot.

Laundry list of problems I know....never really considered foam because everyone who talks about them hated them saying they are cold, hard, and generally uncomfortable.

The AT idea seems like a maybe...can't some of them have the vibram soles replaced by regular alpine soles?

The only thing that will help your pronation is custom soles.  I have them for regular walking and running for track.  I am also getting some for my boots since I have the same problem as you, plus I have the flattest feet you will ever see. 

Solution:
Buy the boot that fits best, although not perfect the best general shape will be the easiest to mold / work with.
Then you have two options,

have the boot manipulated to best fit your foot by the shop and buy custom footbeds.

Or

Intuition liners. Simply the answer to everything (well most things).
their website is www.intuitionsports.com
They make the liners to Dalbellos and Full tilts, though the liners direct from intuition are better. You may know about them through your experience with dalbello. If you didn't heat mold the il moro liners there is no way they would have fit you.
Anyway, these liners expand to fit the boots shape and your foot, so it really is the tightest fit around. It may not solve all your problems but it will be a serious option for you to consider.
i use them and would never go back to a conventional liner. They reign supreme in their market.
You may still have a little heel lift or slight issues but these can be eased out using heel restraints/spacers/whatever is needed.
You also don't need a custom footbed with them as they form to your foot so you save money there, and if you buy them direct, they are not too pricey. (Euro terms, best footbed =70euro, intuition=90euro)

Sorry for the essay but it is something you should consider.
I am not affiliated to Intuition at all, i just believe in what they do.
You must go to a shop with a good bootfitter though.

Peace

check out full tilts man

this sounds like a thread the new bootfitting cult could have devoured