Joe,
One option is to add a small speaker and sq wave generator to make it sound like an ST 60. All kidding aside, usually when a prop is making noise it is a tip shape problem. I have modified numerous props and one way to tell how good it is is to put it on an electric. The best tips for noise are the shaped like the APC props, the Top Flite power tip is also good. For pulling power the square tip seems to be on top but will make some noise in the corners. One trick to try is to sand the last 1/16" of the prop tip angling from the bottom to the top, this is a mod that Hal DeBolt did on some racing props and it quites them down and they pull better (works on 3 blds too).
Best, DennisT