Nope, no funny noises from the blower. Fan turns freely but with a little resistance which I assume is just the motor brushes.
I took a good look around, didn't see any damaged/melted connectors. Used an inspection mirror to see behind the relays on the right side of the car under the dash and all looked fine. Took another look under the driver side dash and it too looks OK.
I've noticed a similar smell in the car before a few months ago, but it was stronger this time. I have the A/C or heat on all the time, never a moment when the blower is off. Just seems strange that it would be such an occasional problem.