Pliable inner boot and injectable fit packs for ski boots

A method for making a custom fitting inner boot for a ski boot comprising:

• providing a mandrel in the shape of a human lower leg and foot;
• providing a custom fitting member over said mandrel, said custom fitting member comprising flexible sheet material formed to define a cavity surrounding the ankle and instep portions of said mandrel with an injection conduit extending from open communication with said cavity away from said material;
• providing an enclosure for said mandrel, the internal surface of said enclosure and the external surface of said mandrel together approximately defining the finished shape of said inner boot, and positioning said injection conduit for access at the inner surface of said enclosure;
• injecting a liquid resin reaction mixture into the shape between the mandrel and the enclosure, thereby to cause said space to become filled with pliable resinous foam;
• at least partially embedding said fitting member therein;
• and
• removing the thus-formed resinous foam and custom fitting member from the mandrel.