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Hi, my dad has bunions on his feet, and while they do not cause him pain they do make finding hiking boots tough. The best he could find were New Balance hiking boots in 4E width, and even they were a little tight. Now New Balance has stopped making boots, and my dad cannot find any boots that fit him. I ordered him every wide boot that Zappos had in his size (10 or so pairs in an 11.5 to 12)...none were wide enough, and not even close really. I think he may have to go for custom boots here. Anyone have any other ideas? As for custom boots, any recommendations (that don't have a multiple year wait)? Thanks!

If you end up keeping a pair of wides... there are shoe stretchers with special bunion "bumps" that can be positioned in different places. The stretchers may tear apart the ultra-light boots.

Red Wing used to make some fairly soft leather boots that would take stretching. The boots were meant to be oiled to keep them supple.

Might try Dave Page in Seattle for advice:
http://www.yelp.com/biz/dave-page-cobbler-seattle

Or try OMC in Portland and ask what widths they have:
http://www.omcgear.com/