Ok, thanks.
I have a set of spd sl and shoes, but really don't want to put them on this bike. Worst case I will get some spd's and new shoes, but trying to avoid that. Riding clipless is ok for a long ride down a bike path (lake shore path in chicago for example, 15+ miles of solid bike path with only a handful of stops), but riding in city traffic, having to carry shoes, always swapping shoes, etc. Don't like it. I'm sure my lack of skill and clipless exp attributes to most of it except carrying shoes.
I guess I will just deal with it for now. Also saw a set of clips that have like a leather padding on the ends. I can probably just rig up my own padding if it keeps bothering me. I really only start to feel it after 10+ mile rides. I did a 30 miles ride last week and my toe actually fell asleep. Maybe I am pedaling with pressure against my toe also.
My foot is definitely in a good position, widest part of the shoes is right over the spindle. And it's just my left toe, right is comfy as can be.
Thanks for the input.