Cycling Hotspot

Okay...as if my crappy knees weren't enough   Just kidding.  I'm trying to tweak out a funky hotspot on my right foot while cycling and I am looking for opinions and suggestions.  The background:

I have had two surgeries on my right foot.  The more important one was for turf toe about 6 years ago.  I don't do so well with surgeries, so my big toe now doesn't really bend and the joint is fairly arthritic (lots of scar tissue).  As a result, my right foot is slightly bulkier/wider/bigger than my left.  I also have the world's worst body mechanics...flat feet, knock knees, etc.  I had similar pains on my old road bike with SPD's.  LBS tweaked the cleats and it never bothered me again.  Wish I remembered what they did   Got a new bike back in April...Dura-Ace pedals.  So I needed new shoes.  I bought SIDI size 40's since that's the same brand/size I had been riding on my old bike.  I figured...go with what works!  Now...what happens when I ride?

The progression of events:
Around 9-10 miles I start to get a numb feeling between toes #3 and 4 (start counting with the big toe as #1) in my right foot and only my right foot.  It almost feels like my sock is stuck between my toes...but it isn't.  By about 30-35 miles, it turns into a sharp burning.  Very distinct, very centralized right in the same spot...base of the toes between #3 and 4.  Gets so bad I can't pedal effectively.  Also get a nasty ache right through the big toe joint.  Today after about 40 miles I was getting a SHARP pain through my big toe joint and it felt like it was popping.

What's been done?  After the initial cleat fitting and realization it was hurting, took the bike back to the shop.  They put some shims on the right side to try to straighten the foot out.  When he put the cleats back on, I think he put the cleat too far either forward or backward and my foot wasn't sitting right on the pedal.  Made it worse.  Took the cleats to another LBS (the one that fixed the road bike cleats two years ago).  He turned that foot slightly duck foot (since that's the way my feet naturally go) and moved the cleat so it was the same distance back as the left one.  Rode today and still had pain.  I even loosened up the shoe as much as I could which helped a little, but the numbness continued...

The following suggestions have been made:
1. Move the cleats again.
2. Need a bigger right shoe

Looking for more opinions, suggestions, or afirmation of any of the above....If anyone is STILL reading you are WAY too nice