I was determined to get it right this time. I started by making a paper template.
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I translated the paper template to the cutting board I've been using for the ankle locks, and cut the piece to size.
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I then did a test fit. I'm ok with between a 1 and 2 mm gap between the foot shell and the bottom of the ankle lock. Here, the ankle lock is resting on the foot shell, so the gap is on top.
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The next question is, where to drill the mounting hole? The hole has to be located such that a screw driver can reach around the motor. I (foolishly) convinced myself the upper left was the way to go.
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But when I mounted the ankle lock and screwed it down, I found that I still couldn't quite reach around the motor. This shows the lock mounted, but not the motor being in the way.
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So I had to drill a new hole on the opposite corner, which was accessible with a screwdriver.
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I did a lot of test driving with this new ankle lock, and it really looks like it's going to work this time.