lets see, the pain is in the blade of your forward foot; your are riding relatively low angles; you are riding with 3° inward cant on the front foot; your forward quad burns while you ride.
That is exactly what I would expect with that list of conditions...
Low binding angles will put more weight on the blade of your front foot if your are moving your hips toward the nose of the board. 3° inward cant will raise the outside of your forward foot, effectively putting more weight on the blade of your forward foot. Your forward quad burns because your weight is shifted forward, which puts more weight on the blade of your forward foot...
I think you get the idea. :)
Here is your web diagnosis; IMO, here is how I would proceed:
only change one variable at a time from here on out, that way you can determine if that variable helps or hinders the issues you are having
3° inward cant is huge!!! Everyone is different and needs different amounts of cant and lift, but unless when you stand upright your knees touch while your feet are 2' apart, I would recommend backing off the inward cant. Ride with more lift than cant.
45°/40° angles are too low for hardboots, I would recommend increasing the angles on that board. Especially since lower angles feel better for you on your narrower board.
the burn in your forward quad is consistent with the majority of your weight being on that leg. Try to ride more neutral with your weight balanced evenly on each leg. As stated by someone earlier, you may be shifting your weight forward because that is how the board wants you to ride it. If that is the case, move the bindings forward on the board and ride with your weight evenly balanced.
Spend sometime dialing in your settings and you will be very happy. There are lots of changes that you can make, if you wait until you get on the hill to make them, it will take forever. Make one change at home, then carpet surf to see if the change was effective. Make another change, test that change, etc...
Good luck :)