Hello! I know this is an older thread, but there is something that fulfills all the conditions in post #1, and then some!
Has anyone tried epoxy+talcum powder?
I stumbled upon this while I was searching for a filler that I could use over expanded polystirene. Polyester car filler was out of the question because of the stirene it emits during hardening, which in turn dissolves the foam boards that I used for the construction of the plug for my composite boat hull.
I came upon the talcum filled epoxy resin by chance, and this has been a great discovery. The epoxy laminating resin is prepared in the usual way by mixing with the hardener in the required quantities and then talcum powder is immediately added in small quantities while stirring continuously until the desired viscosity of the filler is achieved. I use Letoxit epoxy which is an aircraft certified resin and it can be mixed with a number of hardeners in order for different setting times to be achieved. The hardener I use is the fastest one and I still get 40 minutes of pot time, enough for me to apply the filler however I want despite my clumsiness and lack of experience in working with fillers. Talcum is one of the softest minerals, so the filler containing it is easy to apply, easy to spread, easy to lay thin or thick, easy to sand and is more than strong enough thanks to the epoxy. This filler is not brittle like the polyester one and unlike it is a great base for epoxy (actually it is great as a base for whatever comes to my mind except polyeter or vinilester resins).
I get the quantities of talcum I need in pharmacies, especially the ones that are in a hospital. Talcum is used sometimes to dry the backs of long still patients so I can get a bag of 0,5 kg, more than enough for modelling work. Of course there are other sources as well, but this has proven convenient for me.