I've actually never used epoxolite in any application where I needed to sand it that much either. The only applications I've used it for in the past was for making two parts fit together perfectly, with no gaps (like the wing saddle, plug in wings, or plug in stabs). I just put plastic over one part (like the wing), apply the epoxolite to the other part (like the wing saddle), and then bolt the parts together. After it dries I cut away most of the epoxolite that squeezes out with a knife. Which leaves very little to sand to get a nice flush finish.

That's basically what I need the epoxolite substitute for. When I re-aligned the stab tube in the fuse it made a 1/16 gap between the fuse and the leading edge of one of the plug in stabs (for some reason the other side fits fine). So I'll be applying the epoxy/microballoons mixture to the root rib of the stab with the gap, taping plastic to the fuse, and then bolting it on. That's why I need it to be firm enough where it won't run out before it sets.

I was originally planning on using balsa, or light ply, to fill the gap. But I figured the epoxolite substitute would be a faster easier fix.

Thanks again for all the replies!

Mark