Seems like it always costs more than you planned. One thing I read that stuck with me is "proper" ventilation typically costs more than the actual lighting (low wattage grows notwithstanding). In my case that's held true. HID lamps and ballast actually don't cost much. But fans, scrubbers, air cooled hoods, ducting, and the rest add up fast and don't always receive the initial attention needed.
4" vs 6"? The 4" could be fine. Unless it's not. I don't have the experience to say. My philosophy has been: when in doubt, oversize anything that removes heat (and odor) and undersize anything that creates heat. That choice might initially cost more $$ but the flip side is an assurance the plan will actually work. The alternative is a risk. It might cost less time/money to setup using equipment that just gets by. Or it might cost MORE by requiring the purchase of equipment you could have bought on the first go around.
One way to look at it is it's only an extra $66 + shipping to have HTG's 6" fan and filter combo vs. the 4" version. It will cost a tad more in power consumption and WILL be louder (barring steps to quiet it--insulated flex duct goes a long way towards quiet), but those are downsides
I would accept. YMMV.
About making a 6" hole: I guess that's a choice only you can make. But if it matters, I made my pair of 6" holes with one of these...
...purchased at the hardware store. It cuts through the paper of the drywall and then you punch out the circle. I scored both sides but I think they work with just scoring one side too (but the risk of a "blowout" probably goes up). I'd suggest taking your time and going slow when punching out the hole or just use a knife to cut all the way through. It produces a "plug" that might be useful to keep for patching the hole later. Alternatively, I bet even a utility knife alone could accomplish the same thing.
Techniques For Cutting Opening In Drywall
Just ideas.
In keeping with my "you can't have too much air handling capacity" philosophy, I've got an extra 6" exhaust duct all plumbed up that I'm not even using (yet).
You may notice I'm pushing the 6" choice. Understand that's the way I lean but it doesn't mean that's the way you need to go. Maybe someone else can offer an alternative opinion. I just don't want to push anyone into doing things they don't really need to do just because I don't know what the potential of your 4" fan actually is.
$0.02