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@ugosantalucia
Which rim has a 597 ERD? Which hub are you using?
The DT tool is this one (for Aerolite)... not cheap though... for a single build I'd probably use the block of wood
http://www.chainreactioncycles.com/dt-swiss-spoke-holder/rp-prod81460?utm_source=Google&utm_medium=Shopping&utm_name=UnitedKingdom&gs=1&gclid=CP_UyZihr8ICFXQatAod4goARg&gclsrc=aw.ds
In principle the Sapim washers are a good idea and will solve your problem... but most limey you'd have to use longer nipples, which might bring you back to having the same problem... depending on where the thread starts inside the nipple