+ Red = minimal contours (this is our stock body geometry footbed with longitudinal arch & metatarsal button support. Same footbed in all our performance shoes. Same footbed we have used since 2000) = for people with flat foot
++ Blue = moderate (slightly higher longitudinal arch & metatarsal button) = for people with flat to standard arch
+++ Green = significant support = for people with standard or high arches

One of the last bastions of positioning on the bike that is really not taken into detailed account is where the shoe and pedal intersect. But even before you clip in, there's one other detail we've left out: where the foot and the shoe come together. As shoes have become high tech with much stiffer soles, getting it right inside the shoe is very important, and that's where orthotics come into play.

When most people think of using orthotics (padded show inserts) running probably first comes to mind, and then probably something you might use to help someone with foot problems for everyday walking. But thanks to a better understanding of the mechanics of the leg-foot relationship coupled with the advent of stiffer soled cycling shoes, orthotics are now gaining in popularity among the two-wheeled crowd as well. Here at the Discovery Channel Pro Cycling Team camp in Solvang, Glen Hinshaw and Bill Peterson from eSoles (www.eSoles.com) are here to help the boys, and sat down and explained why orthotics are important – and what they can do for you, as well.

"Early in 2000 I met Bill and we started working together on orthotics for me," said Glen (who also rides for the Discovery Channel Masters Team). "I had a 'hot spot' that I just could not get rid of, and we figured out that I had a collapse in one of my arches that was putting all kinds of things out of balance. One we got that diagnosed and the correct orthotic made through laser alignment, I saw more power and was able to ride longer because the fatigue factor was removed from the structural breakdown associated with a poorly aligned body."

Glen then went on to note that many times we try and solve hot spots purely through making cleat adjustments on our shoes. While this certainly can alleviate some problems, more often than not it's the alignment of the foot that's the problem, not the cleat position.

Bill, who's been creating orthotics for over 25 years, noted that all of the conventional methods are not reproduceable. If you get a set made from plaster casting, that's great, but when you need another set you essentially have to start from scratch all over again. "With our technology, using 3D laser scanning, it's all automated and we can recreate the insert over and over again as it's needed."

So what is the process? It's not time intensive – most of the riders were done in 15 minutes or less, but it is thorough. First you get a foot alignment evaluation consisting of seated and standing examinations, looking to see how your feet occur naturally with little weight bearing and then with full weight bearing. A certified specialist measures degrees of pronation on during this process and the data is recorded. Then you sit with your foot in the 3D laser scanner bed, your foot gets aligned and then an inflatable pillow ensures accurate contouring as your foot is painlessly scanned into the computer. By knowing the impact of the data from the seated vs. weight bearing exam it's then a matter of the computer creating a perfectly sculpted orthotic that will literally fit your foot like a glove, err, sock…

"We have different densities of foam based on a rider's style," said Bill. "This is essentially driven by the amount of watts a rider can generate on a bike which related to weight transfer. The starting point for all of that is the simple question: how much do you ride a week, and then of course the caliber of the rider. Pro riders, riding thousands of kms a year, will get the heavy density – something very firm and positive, while the recreational rider may want something a little softer due to less pressure on the pedals."

* Something very few orthotics ever take into detailed account: the shape of the shoe platform. Most off-the-shelf and semi-custom inserts you just shove into the shoe and hope for the best. Not so with eSoles. They have a template for practically every make of cycling shoe, and once they know the one you use the orthotic will be cut to fit perfectly in your gear. So knowing this, and having your foot on file in the database, it’s possible to order multiple sets of orthotics (even at different densities) for multiple sports and general walking.

While a new product to the team as a whole, George Hincapie, Levi Leipheimer, and Tom Danielson have been using eSoles for some time. "Most of the top American riders are clients and we also used the DC Masters team to help experiment with prototypes in the early days," said Glen. "And while the custom based experience like we're doing today is our starting point, we're also branching out into a self-service model soon as well." OK, OK – I know you want to know: what’s it going to cost? "The full custom orthotic is suggested between $199-299. A lot of the cost is based upon the practitioner that is doing the evaluation and the other information that needs to be taken into account. And we hope to have a semi-custom process by the latter portion of this year that will be under $100."