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Al,
I think you need to do something to energize the
boundary layer. If you can't divert it you need to put some energy into it. It
is probably getting slow and separating from the face of the duct. That is what
your data seems to indicate to me.
I like the shape that Thomas proposes better than
what you have now, however, I still think you will need some VG's in front of
the inlet.
I know it may seem counter intuitive, but
turbulence may actually help in this case. You will not get very efficient
internal diffusion, but it will be a lot better than what you have now. I don't
think that putting a turning vane will help too much without doing something to
energize the boundary layer first. You'll just have a slow thick low energy
layer, and a high energy layer separated by a turning vane.
It is really easy to duct tape some aluminum VG's
in front of the inlet and see what it does.
You may need a combination of Thomas' contour, VG's
and a turning vane. Go with the easy fix and work your way up in
complexity.
Monty
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