pain in big toe joint 5 months after surgery, need advice

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I went in for joint fusion surgery on Dec. 6, 2010 and it's May 18, 2011. Luckily, instead of fusion I ended up having bunion surgery plus arthritis surgery. The pain is intense now, worse than before. The surgeon says the joint has healed and is fine. The physical therapist, whom I see once a week, gives me a number of daily exercises, and I have improved. I still have to walk on the side of my foot, however, due to the pain. I can walk about a block. I have lost about 90% of my normal daily activity (I was very active). HELP! Neither the PT nor the surgeon sees anything wrong with the results of surgery. I am 43, in good shape otherwise. I work out at least 3x/week, even with this problem, although it is mostly upper body and modified yoga. I don't know what to do about the pain. I am weirdly unaffected by oral painkillers (not a good thing to find out post-surgery) although liquid morphine helps, ha. I don't want any drugs. Shall I seek another PT? Mine seems great, is highly recommended. The surgeon says I should be fine and that there is no particular reason I should have this pain. Any advice? I can barely walk.