canklecat, noglider;

Thanks for the ideas. Favero did respond and confirmed that the axle placement is the same for both cleats. That seems to leave training as the only variable: I started using TrainerRoad this year (and bike, shoes, cleats and socks are the same as last year). I think it might have been due to a breakdown in form after having gone out too hard on the first four passes (of the Death Ride). The pain did abate somewhat when I focused on technique. I'm familiar with bunion pain; I resolved that 5 years ago by removing excess, overlapping material from my old shoes, and my new ones have never been an issue.

The good (and bad) news is that next year's Death Ride will be 29 miles shorter - they're closing Carson Pass and making it a century ride.

Thanks again,
Nick