perhaps its time for liquid cooling? Seriously, a 6" booster fan on its own pushes AT BEST 160cfm... its what "booster" fans are designed to do. 160 free air movement, 240 pass thru w/ a real fan at one end....
So at 160cfm thru a 6" tunnel.... what is the god awful noise your hearing if it's not mechanical? Maybe you got the wrong brand n its got a loud motor or something? I just can't imagine this amount of air movement, or this small and low power of a fan is producing noise to a level of irritation...
Also... Is your fan connected direct to the hood? Cuz that sounds like it'd be noisy as hell.....
hood, duct, fan, duct to exhaust port. Mount/hang the fan. (i like rubber bungee straps w/ a piece of foam behind so absorb vibrations. Eye hook on either side to hook to. Foam I use comes from local old lady yarn shop, lol.)