Hi Dr. J!
I had a v-cut bunionectomy in Nov 2007 on my right foot. After the surgery, I did extensive physical therapy for 6 weeks but still had limited ROM, so the doctors determined that my screw needed to come out to regain some of that range in March 2008. More physical therapy after the screw removal for 3x/week for 3 more months--still to no avail. I continue to have stiffness in my big toe (I can't bend it at all), SLIGHT swelling between my big toe and the next toe, and a constant burning/soreness around the base of the big toe joint stretching around to the ball of my foot, mainly around the sesamoid area. I still can't fit my foot into anything other than a flat shoe without pain. In addition, I have been shifting all of my weight to the right part of my foot, so now I have lots of soreness around the base of my pinky toe.
Here's the fun part! After this, my THIRD opinion, my doctor ordered an MRI of the foot, and has discovered that after a year and a half, the v-cut of the osteotomy is as clear as day and apparently not healed!
If this really is the case, and this is a malunion or non union of the original cut in the bone from 2007, what is usually done in situations like these? Is this a normally occuring condition? Can bone stimulators be successful on fractures like these? I also used a bone stimulator after the second surgery 2x/day for 20 min for 2 months, but apparently it didn't work

I've heard some things about bone grafting...I am hoping that, if necessary, that is not an invasive procedure and that the post-op care isn't extensive and will keep me off of my feet. Does it involve a cast?
Sorry for all of the questions--I just feel like I've been thrown for a loop here!! Any thoughts you have would be great!
Thanks so much!
K