I had the same problems that you describe, and here is how I resolved them, and now have a really well working fogger system that has gone through 2 grows using the same fan.

Things you need:
1 five gallon bucket with lid
2 dryer vent connectors (through wall, or flap style, not sure what they are called)
4 feet of dryer hose
some pink stuctural foam (I also use this for my tray cover
1 24oz plastic paint cup
zip ties
2 1.5 inch pairs of bulkhead connectors 1 F 1 M
1 60mm fan from radio shack
1 multi voltage output transformer.
small zip ties
fogger

I probably need to post some pics of this setup, but here's how you put it together

cut out a peice of sturctural foam that is small enough to fit in the bottom of the bucket
cut the center out to fit the small paint cup
cut the paint cup to a little deeper than required for the fogger
drill holes in the cup
drill some holes in the foam
mount the cup to the foam
mount the cup and foam to some dryer vent hose using some zip ties
cut a hole for the vent connector in the lid for the bucket
cut 2 holes for the bulkhead connectors
mount the vent connector in the lid and connect the vent to it on the inside
duct tape the fan to one FA
make a cap using an end cap and a small peice of pipe for the other one
cut a hole in your table top to mount the other vent connector
run the other peice of hose between that and the one on the bucket

use the second hole in the lid for checking ph and ec and filling the bucket between nute changes.