I've done it by forming a mold around the heel and filling it with resin.
I made the mold from heavy waxed (rubbed with a candle) cardboard and used duct tape to stick it to the shoe/boot. I used 2 part mix liquid resin that I bought at a boat store, it's sold for making fiberglass repairs.
The result was solid, durable, and heavy.
Be careful of:
- Fumes from the resin (do outdoors and entertain the neighbors)
- Too thin mold material, it will bulge and the heel breast will end up curved.
- The tape seal leaking, what a mess! (and that's the end of the boots)
- Keep the boot level so the heel will be flat.
- Don't overfill. (see #3)
The surfaces will need a lot of sanding, and you'll have to add rubber bottoms or the heel will be noisy, slippery, and chip.
On second thought, ignore this post
