Re: Metal boots? Well... in my idea a large part of the back would be detatchable, to allow the foot to enter, then fixed back in place using rigid fastners - thinking of motocross or ski boot style over center closures. If the boots are molded from a composite material, you could build in locating bumps and places to attach the closures.
Having said that, I'm not sure the best way to start something like this. The actual lay-up of fiberglass or carbon fiber wouldn't be too hard. Getting the last/female mold would be somewhat tricky, short of taking an existing pair of boots and filling them with a molding agent, then laying composite cloth/resin over that. |