One piece missing in the OP's post is info about the height of the instep vs. the length of his foot. Did the fitter(s) measure this? If they didn't use a brannock scale and soft tape measure, Its likely been overlooked. For some, this can be more important in determining shell size than the length. We fit a gentleman a couple of weeks ago in an Atomic Hawx Magna 26.5 even though his foot measured 25. His instep measure was 28.5! The Magna has a high volume instep (as does the prime!), so one shell size up accommodated the volume of his instep nicely, and we still had some 5th met work to do along the entire length of the fifth met! Many other boots would still have been problematic even in a 26.5. Another possibility is the ankle bones are not naturally aligned with the ankle bone pockets in the liner. The right pressure in the wrong spot directly behing the ankle bone (lateral malleolus) on the nerve bundle can also create tingling and numbness even if everything else is working well. Anyhow, hope the boot chosen in round two gets everything sorted!