It sounds like you want the efficiency of a counterflow chiller with the trub benefits of an immersion chiller. I don't think the disc idea will work for the same reasons PGEduardo has already listed. You have to keep in mind you're chilling a thermal mass that wants to constantly find a point...
I did something similar to this awhile back with a 30" sprinkler riser, sprinkler head, 1/2" ball valve and 1/2" MPT to hose adapter. I already had a 1/2" ball valve laying around so the total cost was around $5, would be $10 with a valve.
Polystyrene and polyiso rigid insulation boards are both qualify as a vapor barrier. Just put the boards on the inside of the framing and use silicone sealant at all the seams. If you want a belt and suspenders approach, you can put a layer of FRP panel on there too.
What's the reasoning behind a space right next to your burners for a steel fermentor? You could just build a separate furniture dolly for the fermentor and roll it up to your BK after flame out.
Dissimilar metals in contact can cause galvanic action where one material begins to corrode the other, they can eventually become fused together. http://en.wikipedia.org/wiki/Galvanic_corrosion
Easy fix, just grab 2 rubber washers or o-rings to isolate the metals from each other.
I generally go this route when brewing a big beer, and to echo other posters, it's a better practice to harvest yeast from an oversized starter then to wash the yeast after primary. Not to mention, it's much easier.
The Pilser needs to be cooler. The fermenting liquid will be slightly warmer than ambient temps too, all that yeast activity can drive temps up another 5-10 degrees. All yeast strains have an optimal temp range specific to that strain.
Grab a bunch of liquid crystal thermometers for the...
Their rare stuff doesn't see any distribution, the seasonals see limited distribution and are generally sold out within a day or two. Flood seems to hit D&Q pretty often with seasonal releases, and Brandon always tweets out when new bottles hit his store.