I had the exact same problem. Ended up switching back to X2s and eating the cost of the Zeroes.

That's odd. With the screw all the way out wouldn't the heal of your shoe be hitting the chainstays? My feet have to come out too, or risk weird knee tracking. I have the float set as far as possible without hitting the chainstays. There's still plenty of adjustment left for toe out, but there's just no room to toe out any more.

I solved this years ago by inserting shims under the cleats to tilt the feet outward. Can you try that?

Edit: almost forgot. Speedplay has longer spindles for their pedals but they aren't available at the stores. Need to send the pedals to them to install a longer spindle.

Assume you tried to adjust cleat position on shoe to accommodate heel out? There is a surprising amount of play/adjustability on the 3 bolt setup, not to mention the variability in the shoe mounts across brands. I have zero's on a new pair of Bonts and I had to close down the heel out screw past halfway due to mounting position.

Right. For max toe out the cleats need to be installed all the way in.

Cleat in > shoe out > more room to toe out > if you need more room then you need a longer pedal spindle > if maximum toe out doesn't correct your problems then it's probably time to look at shimming the cleats.

Check this out:

http://www.stevehoggbikefitting.com/...OSITION2-500x666.jpg

Shoe on the left has a midfoot cleat placement. Shoe on the right has the cleat slammed to the inside, and you can see why. The toe out screw is almost all the way out.

I need my heel out as much as possible, so I don't have a problem with the chainstays. Sometimes my toes rub the crank, but thats not too much of a problem.

I have tried moving the the mounts, but I can only get them to adjust forward and backward. I need them to adjust left and right. I'm trying to put them on a pair of shimano TR5s, which is suppose to fit the zeros.

Did you mount the cleats with a torque tool? If you tighten the cleats too tight, you can restrict the float. Speedplay makes a 2Nm (or maybe it's 2.5Nm...) torque key that you should use to mount the cleats.

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No, I don't have a torque tool, but I'm pretty sure I didn't tighten it too much. I could move my foot side to side very easily, but for some reason all of the movement was toward the bike and I need my heel to move out away from the bike.

I just decided to use the zero on my right pedal and the light action on my left. That might not be smart, but I did a time trial today for a race coming up in a few weeks and they seemed fine.