This wouldn't be if I could make a Batman movie, this is just who I think would be best for each role. I wouldn't have this many villains and such in them.
Bat-Family...
Batman: No complaints with Bale so far
Nightwing: I like the Drew Fuller and Padalecki suggestions. They could work.
Robin (Drake): Joseph Gordon-Levitt
Batgirl (Barbara): Not sure...maybe Rachel McAdams, but she might not be able to pull off the physicality.
Huntress: Eliza Dushku definitely seems to fit the role well. Nice choice.
Alfred: Might as well keep MC.
Fox: Freeman all the way.
Villains...
Joker: Vincent Cassel or Adrien Brody
Harley Quinn: Brittany Murphy
Catwoman: Kate Beckinsale in a second. No second choices.
Dr. Hugo Strange: I have no clue why, and I'm hating myself to say this because he isn't a traditional actor, but Penn Gillette. He'd have to seriously calm down though.
Lyle Bolton: Some wrestler or something, since I wouldn't give him more than like three lines of dialogue.
Riddler: Edward Norton
Mad Hatter: Martin Short
Two-Face: Liev Shrieber
Mr. Freeze: No idea. You wouldn't have to cast someone who is already bald. You could take someone and shave their head, so that leaves like any white male actor between the age of 30 and 50s open for this role, theoretically. I'd have to hold auditions.
Firefly: Who cares, he's in the suit the whole time lol.
Penguin: Robin Williams. Ok, I know, that's a little weird. But hell, the guy's been begging to be in a Batman film for over a decade. He could look the part with a little prosthetic nose, and Penguin isn't exactly the most serious of villains. You tell Robin to tone it down a little like his One Hour Photo days and he could do a pretty good job, plus it would make him happy and draw crowds.
I would agree with you, except, Sarah Michelle Gellar is to short. How about Kristanna Loken as Batgirl? I have always liked Milla Jovovich, so she as Catwoman would look good.