I created a mold out of bondo. I shaped it as per all the pics i have of the shoe armor, then made an exact bend. Now I just heat the sintra then slap it on top.
Go here and click on 'Shoe Tree' http://www.rstco.com/
Would something like this help out with that? I mean, just use the shoe tree as a base, and build it up with some bondo so as not to waste.