Sounds like a fun project!
Actually, just yesterday, I also replaced the stock fan in my cheapo 300W TTGI PSU after cutting out and filing the stamped hole. I also swapped it with an 80mm Fanaflo low, and I put rubber washers between the metal casing and the fan to reduce case vibrations.
I saw your problems with the molex connectors. Just what happened? Were you trying to unplug the molex connections in order to swap in the new fans? In such a situation, I find it to work well when you snip the wires a few inches from the connection, put some heatshrink tubing around the leads of the fan, twist the wires, solder, and then slide the heatshrink tubing over the solder joints.
Because the original config of the system varied the fan speed with temp, splicing the fan in has retained this temp-controlled feature. (No 7V modding required, which is nice for simplicity's sake, as well as for the fact that if for some reason the PSU starts warming up too much, I can count on the fan kicking in to where it needs to be.)
I also removed some of the punched slats on the front side of the PSU to enhance air circulation through the unit, although the dremel started running low on batteries and I was getting low on patience and stopped early.
Even with a tungsten carbide bit, it took some umpfh to get through the steel!
All said and done, the air coming out of the PSU now is cooler to the touch than it was before the mod, and the PSU is for all purposes silent. Now, all I can hear is the fan on the Ti4200.
Oh, and on a point you raised much earlier, I've also found the Panaflo LO's to be substantially quieter than the Vantec Stealth fans, ratings notwithstanding. The fluid bearing has a lot to do with that, as well as the fact that these dBA ratings aren't all that accurate to begin with ...
Well, at any rate, best of luck with your mod!
-- Paul
PS: One question: If you were to replace the fan / cooling system on your Ti4x00 today,what would you choose?