Making a nice bed cover to convince friend
 

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?

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?

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