Why wont this pad close / fill if i set the line thicknesses to zero?
If I use polygon it fills but there is no way of adding the arc / cutout.
It is just how it is 
only polygons fill every other primitive is just the primitive itself.
So i suggest approximate the shape with a polygon and define the final outline with a border made from other primitives.
you may have a look at kicad StepUp for complex pad shape footprint generation
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