I have600mA load that needs to be ~230 DC powered.
Using Smoothing capacitor is most straight forward solution, but I assume it would need resistance, or this 100uF will make fuse blow, especially on switching on moment. And 1A rectifier would be way too low.
Thought of using choke to prevent inrush current, but even 100mF chokes are expensive for this sort of current spikes.
Other option would be using thermistor, however I am unsure what values should I aim at.
If I would like to connect smoothing capacitor without any resistance, what rectifier amperage I should aim at? 16A?
And yes, all connected to live, without transformer.

 

A good solution would be to use a thermistor current surge limiter and rectifier, both rated at about 1A.

 

Question is, what values I should aim at, if no resistor added we are speaking of 4,5A spike cap charging current, enough to fry bridge. And that is on regular work, turn on charging current is even worse.

 

And 1A rectifier would be way too low.

If you look at the spec ofr a 1A rectifier you will find they also have a surge current rating which is way higher than the continuous rating.
For instance, for the 1N4007:
Average Rectified Output Current (Note 1) @ TA =+75C IO 1.0 A
Non-Repetitive Peak Forward Surge Current 8.3ms Single Half Sine-Wave Superimposed on Rated Load IFSM 30 A

 

Now when I am thinking, I do have old fluorescent lamp ballast lying around, would it work as a choke? these things are rather robust, made for 40W lamps.

 

Now when I am thinking, I do have old fluorescent lamp ballast lying around, would it work as a choke? these things are rather robust, made for 40W lamps.

According to this
"Your typical 40 W 48" tube is supposed to run at 0.43A., start at 400 - 650 V and have about a 93V working voltage."
thus the ballasts are designed for about 430mA.
You'd need to measure its resistance to see if it would overheat at 600mA.
Otherwise that could possibly work to limit your surge current unless the core saturates with a low resistance load.
Try it and see.