The Template is not fit for purpose. It is for a free body moving against a ground plane. An aerocap is a special case. It needs to transition from a tight fit against the cab to a low arc at the tailgate,
pace aerohead.
http://ecomodder.com/forum/showthread.php/baby-template-car-darko-2016-a-32673-26.html#post537059
Here is how I laid out streamlines:
Here is the material I would use, Polymetal is stiff as 5/8" ply and skinned with aluminum. More expensive, but prefinished:
But 1/8" ABS would be better that acrylic. This is for a teardrop, but it shows how you could use large sheets with minimal cutting. Think Armadillo:
