Making a nice bed cover to convince friend

[MPGranger]

My buddy and I both have white Ford Rangers. His a 2001 3.6L manual and mine a 2010 2.3L manual. I have gotten him interested in hypermiling, probably as a way to buy more guns! lol

Anyways... my temporary grill block looks cheap, it's just duct tape. So I am planning on doing a bed cover, neither of us have one. So I want to make it look nicer.

I've seen some tonneau made with a wooden frame; I'm planning on doing a 2/3 and 1/3 section so I can take bits apart as needs be.

Anybody have any tips or secrets that they wouldn't mind sharing?

[MPGranger]

So my bed is 54.5" wide and 72" long. I want to do a 1/3 cover and a 2/3 cover. I also want these covers capable of switching places and staying in place without the other, just in case I'm hauling something around. So that's a 54.5" by 24" panel and a 54.5" by 48" panel. Now polystyrene comes in 48" by 96" panels, which irks me because square area I should have enough to make my cover. So my 2/3 panel will be solid and the 1/3 panel will be made up of two 24" by 27.25" panels, leaving me with a 48" by 14.25" panel left over, anybody have any ideas of what to do with this?

Does anybody have any experience with attaching polycarbonate to polystyrene?

[brucepick]

Use OSB plywood?? Prime it gray and paint it black.