Abstract Stress fractures of the second metatarsal are well reported, and usually heal spontaneously after identifying the aetiology and modifying activity. A unique case of non-union of stress fracture of the second metatarsal following talonavicular arthrodesis for Mueller–Weiss syndrome is presented here. A 34-year old male was presented with forefoot pain 18 months post a talo-navicular arthrodesis for Muller–Weiss syndrome. The foot was swollen and tender over the second metatarsal. Radiographs revealed diaphyseal cortical thickening, and a diaphyseal fracture of the second metatarsal. Conservative treatment failed to achieve union. DEXA scan showed normal bone density, CT scan confirmed non-union. The metatarsal non-union was subsequently freshened, bone grafted and fixed with a small fragment plate; union was achieved at 8 weeks post-operatively. A second metatarsal stress fracture non-union secondary to altered mechanics in the foot as a result of talo-navicular arthrodesis is presented here with a literature review.