And the Nexus is just a Yate Loon that already has a voltage dropping resistor built in so they never actually run at 12V anyway. Noise can also be due to the design of the fan blades but, as you said, the motor is usually the source of most noise. IMO, fan blades with square corners on the ends will generate more noise than blades that are shaped like propeller tips at the ends, but the square ended ones will likely move more air than those with rounded ends because there is more surface to grab the air. Another trade-off... Quality and loudness of noise can also be affected by fan orientation - sleeve bearing fans tend not to like horizontal orientation very much.
Using a Zalman or Sunbeam bracket, a 100, 120 or 140 mm fan could be located right up next to the heatsink w/o actually having to be mounted to it. That way you wouldn't have to chop the fan up while also taking some weight off the fan mount.
And if you plan to use the Fanmate that comes with that HSF, test it with the fan you're planning to use. The Fanmate is a PWM speed controller - some of which can cause some sleeve bearing fans like the YL/Nexus to buzz and some ball bearing fans to whine. Apparently Zalman didn't bother to do that so the OEM fan buzzes when adjusted (according to the SPCR modding article)... :roll: According to G-Y, high speed, ball bearing fans (designed to run over 4-5000 RPM) can rattle when slowed beause of the higher tolerance bearings necessary for high speed operation.
I hook my CPU fan directly to my Sunbeam Rheobus fan controller which is a linear controller and doesn't directly contribute to any fan noise changes. I think one of the cheaper Vantec controllers is also linear. The cheap Silverstone one is just resistors - totally passive, so it shouldn't add any noise either.
I tend to prefer ball bearing fans as they can actually push some air and generate higher static pressures than sleeve bearing fans (good characteristics to have for heatsink use). You might want to try the Nidec 92mm sold at bgmicro.com et al. for your experiment. At least Zalman did design their fan mount so that changing the fan out wouldn't be too difficult - perhaps an indication that they don't have a lot of confidence in the longevity of the OE fan...
.bh.