About the fan washers:
I am not sure of the purpise of those washers. But if they are intended to decouple the fan for vibration dampening, it would make more sense to have to washers installed between the screw heads and the fan itself, not between the fan and frame/rad.
About the Alphacool screw lenght:
The gap between the rad screw taps and screw protectors can actually vary from rad to rad, and even from side to side on the same rad. So measuring mine would do no good for you. Generally, you measure the thickness of the stuff you will be attaching to the rad and add an other 5mm. For example if all you want to bolt on is a 25mm thick fan, you just use the 30mm screws provided (the shorter ones).
If your screws are just a little too long for your need, you can always put some washers under the head of the screws to compensate for the extra lenght. If your screws are too short, well, you are screwed (pun intended)
On one side of my rads, I have only the 25mm fans, so I used the 30mm screws for that. On the other side, I have the rad bracket from CS, the 25mm fans, and some fan grills. So my 35mm longer screws supplied by Alphacool just fit perfectly there.
And you will be putting 4x 480 rads in your case? That is a HUGE amount of raddage dude, and all in p/p too? Gawd man, you should be ashamed of complaining that you can't have all 60mm rads. Shame on you!
And I had to make some fairings to allow my rads to stick out on both sides of my STH10. I just miscalculated my rad thickness so I had to do this in order to preserve p/p on all my rads and have comfortable room between rads to allow for good air flow, cabling, and piping. Here's the result. Not seen is the Demciflex dust filter that will cover the whole thing:
I don't know if this idea is good, or not, for you if you want to preserve all 60mm rads.
I was afraid it would look ugly. But they look like they were factory installed and they actually break up the otherwise minimalist industrial square look of the CS case. Maybe the idea doesn't help you, but it doesn't hurt to throw it out there.
I know this is your first build, and so you have nothing to really compare it to. But how do you like your 'little' TH10 so far?
Edit: the 'little' abjective for the TH10 was obviously sarcastic. That freaking thing is a monster, as in my STH10.Edited by PepeLapiu - 3/2/14 at 10:10pm