Quote:
Originally Posted by
M Code 
An interesting project...
But again my question is
why do major surgery on the chassis to fit in the larger fan....

It is pertinent to note that Noise Blocker actually has a
replacement 40 m/m fan that would drop rite in
without any metal work & cutting..
It is called the Black Silent Noise Blocker, thus one can take advantage of the lower dB by simply installing a
drop-in component.
My other concern would be the
increased wattage draw of the bigger fan could exceed the design limits as it is 3x of the OE video fan which
significantly increases the risk of possible component failure in the 7550HD power supply.
M Code, that fan
is the 40mm "Black Silent Noise Blocker" (XM1)

The stock fan is 30mm hence the modification required to fit a 40mm unit. NoiseBlocker doesn't have a drop-in option for us. The OP of that modification could not source a 'silent' 30mm which is why they went with the 40mm. If an ultra low noise 30mm fan could be found, that would be ideal as no modification would be required (However, a 'silent' version of this size would most likely have considerably lower CFM than the stock unit and may not provide adequate airflow)
You bring up a valid point regarding the wattage draw, do you have a specification for the stock fan? That particular fan (NB XM1) draws a mere .36w. Fan's
comparable to the 7550's 5000rpm/30mm video fan draw ~.5w+ and it seems unlikely the stock fan is only ~.12watts. Again, I have no specs for the stock fan besides the RPM and size to judge from, but if the replacement's current draw is the same or lower there should be no risk at all.
I should mention, on both of the 7550s I have/had, the video fan (in their properly operating, non-squealing state) doesn't seem
that intrusive. Albeit a much lower tone the main amp tunnel fan is more audible when it kicks on, and would seem more worthwhile to replace with a quieter unit
if replacement was ever required. Only problem is that it looks to be a major PITA to get to!