Al,
Re: Orange peel effect. Agreed. But I acknowledged, about four posts ago, that the thickness of the heel stiffener would affect the final location of certain elements of the shoe/boot. A thicker heel stiffener will surely affect where the ends of the tabs lie. What I'm not so sure of is whether the relative thickness of the heel stiffener will affect the *fit.*
When you design a shoe with a lining you have to design the quarter lining different than the quarter itself....because of the orange peel effect. You have to design with the thickness of the heel stiffener in mind otherwise you'll end up with a lot of surplus army goods in the leather that covers the heel stiffener.
When you design a pull-on boot...at least the way I was taught, and, I suspect many cowboy bootmakers do...the patterns we have, usually have the orange peel effect implied. For instance, if you design a paper top pattern to measurements that you know will work (important point), and then cut both top and top liner to those exact measurements...and *then*...assemble the tops inside out, for one reason or another the orange peel effect becomes virtually moot. And without significant features such as tabs, etc., to locate with any precision (the vamp of a boot is essentially featureless), why worry? The fit won't be affected.
Then again, if you always use the same thickness of heel stiffener (within an iron or two) what discrepancies do exist in the location of such features as toe stitching, or foxing, etc, will be almost negligible and easily compensated for. What I'm getting at, as sidebar to my main point about fit, is that whatever effects that the "dreaded orange peel effect" has on shoes is either already built into the patterns for boots or beside the point.
Alright, that's *my* story and *I'm* sticking to *it*

except to say one thing...I don't know squat about making shoes compared to you and some others posting here. So take what I'm saying with a large grain of salt.
Tight Stitches
DWFII--Member HCC