Yeah the Allen Edmonds I have are all slightly tight in the toe box but they're close enough where I have worn them many hours. I have a low volume foot, moderate arch, ball of my foot is somewhat wide ( probably an E width at the toe box)That’s interesting. Do you have a low volume foot? I have little experience with AE, but I did have a couple pairs on the 65 years ago and a D width in that last was incredibly narrow.
The smokejumper last, not the 55, I’ve read is more narrow so maybe going to an E would make sense. As far as a full size down from brannock, maybe there’s more experienced people that can answer as I’ve only tried the 55, and the C641 lasts and half size down was spot on.
I also ordered a custom pair of Nicks Builder Pros for work and they sized me at a 9D with a try on pair. Their sizing is supposed to be similar to Whites. So I'm just hoping that if my Bounty Hunters come in slightly short that I won't be screwed and out $600 for boots I can't wear