I have a few contributions I don't think have been mentioned, but I have only read through the first 8 pages, so I apologize if I am stepping on anyone's toes, just think of this as seconding your nominations if such is the case.

Marcone - Ray Stevenson - any Dexter fans might be inclined to agree.
Andy - Alexandra Daddario - Google
Nicodemus - Gabriel Byrne or Mads Mikkelson - someone has to have said this...
Sanya - Quentin "Rampage" Jackson - I see Sanya as a mostly happy character
Charity - Gina Carano - Could forge armor with a hammer, too short for Gard.
Liver Spots - Kelsey Grammer - he can play it cool in book 5 and really ham it up for book 7
Red King - Mel Gibson
Butters - Robert Picardo - might be getting up there in age though
Michael - Craig Bierko - I can think of a few older actors that might be better, but I think he would do a great job and is close enough in the age range
Mavra - Helena Bonham Carter - She dirties up perfectly for the role
Steed - Tom Hiddleston - come on, he's perfect for it
Grevane - Sean Bean - Because it's an awesome role and he dies at the end.
Alicia/Luccio - Nina Dobrev - I just think she fits
Paolo Ortega - Josh Hartnett - Close enough in looks and would pull it off really well.
Kincaid - Christian Slater - I just think he would be perfect for someone Harry hates but the audience loves
Gard - Kristanna Lokken - fits the build and can act the role
Bianca - Vanessa Marcil - that's who I picture in my head almost exactly
Murphy - Alice Eve - would fit pretty perfectly
Sarissa - Laura Vandervoort - especially perfect since I agree with Charlize Theron as Mab.


That's far from a full list because a lot of the others that are notably left off I happen to agree with.