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@almac68
Matt (baddesigner)
I agree with Scrapper and it's possible that your feet will need time to adjust.
Have you considered switching pedals? cos everyone has a different pedal stroke style. Bikefit might have the answer. That kinda consultancy ain't free though when all you maybe told to add a wedge in the cleat and they are after your business so will push to sell..
I ride on Speedplay free float pedals / sidis for long road bike trips outta town, straps and trainers on FG bike in London upto 40 minutes journeys, so the stress is not continous in one place, and suits me fine.
I'd suggest you make as many adjustments, even alter your pedal style regularly.. we were taught this when riding very long distances there is a foot shuffle (like dragging the feet backwards) when spinning, these tricks improve your endurance and well as rest feet parts that maybe taking a pounding.
either that or you soak your pins in vinegar over night and HTFP.. peace