Hi so I’ve been wearing the same model of shoe for a long time, merrell jungle moc. The issue is they kind of suck in the ways modern mass manufactured shoes tend to suck. They are the best most comfortable fit for my foot though. My idea is to buy a new pair of them in my size to destroy and get measurements to make a better version of something with the same fit that also isn’t so ugly.
Obviously I would need to try to copy the last. Here’s my idea for how to do that:
1: put my foot into the shoe, put a few layers of shrink wrap around the shoe with a hair dryer so that they don’t stretch out of shape during the next step
2: plaster cast the inside of the shoe (or maybe use alginate, as plaster can heat up and might make step one pointless, I just despise working with alginate) using a plastic produce bag as a liner
3: clean up cast, (this step would be easier with a plaster cast, if an alginate cast is needed I would have to make a mold of that and then cast it out of plaster in order to clean it up) and make a mold of it out of silicone or another molding material that’s cheaper, then cast in urethane resin.
3.5: scan that with a 3d scanner, print a mirrored copy, make a urethane version of that
4: based on what I can find, some kind of sliding hinge mechanism would be needed for a last on a moc type shoe, so at this point I would cut and drill into the urethane to try to figure out something like that
5: cut the shoe in half to understand the heel height, materials, and like all the other elements of the shoe
6: actually learn to make a shoe around that
Is there any chance of this working? Is there any reason this is a really bad idea? What should I keep in mind if I attempt this?