Thanks, Phil! I'll take you up on that.
Sure! On the left is the new style AFD, and on the right is the original AFD sans teflon strip. I don't have a picture of my toe handy, but its features match the toe on the right not the left.
So I did a bunch of dremeling on the AFD on the left to thin the raised features, and I still have a slight (1mm?) gap between boot and AFD. Before anyone asks, my boot soles are pristine
The gap is not heinous but is slightly noticeable when skiing (I can feel my toe click up and down very slightly if I force it). I think there must be some other changes in the dimensioning of the new vs old metal toe style and AFD pair. E.g. I think the AFD sits a bit higher in the old design than the new.
I'm not sure what there is to be done besides either finding original AFDs or putting a small shim under these AFDs to flex them upward a bit and close the remaining gap. When I asked Rossi, they said that the new AFDs should just work.