Long shot but what are you using for cleaning and conditioning? I just checked my Bayfields and mine are extremely stiff in the toe cap. I treated them like a normal hunting\hiking boot for the first few months of this winter and never used trees and put them through pretty rough conditions. I agree once they start creasing (or rolling, good description) in the toe box it really changes the look in a detrimental way. I've never seen any thing like yours either.