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...I was wondering about the feasibility/practicality of joining the cab and bed by basically just cutting a hole in the back wall of the cab.
It's not feasible or practical to mechanically join the bed to the cab. You can cut an access hole, but 150 sq.in. is pretty big. Don't cut near the corners, and don't leave sharp corners or stray cuts from the holes.
Originally Posted by germh
...package electronics in the bed and have access to some ports and run fans and whatnot from inside the cab...
It would be better to just mount the ports on the cab wall, using extension cables; or run them all through a flexible conduit between the bed & cab. If you want to supply cool air, create a duct from the dash/floor-console ventilation into the bed, but make it flexible where it passes between the cab & bed. A dedicated refrigeration system would probably be better, though; if not compressed refrigerant, Peltier (thermocouple). But if you really have to have such a large hole, install a flexible seal between the cab & bed, like the inflatable ones used for sliding rear windows into camper shells from the 80's & 90's. But make it more-durable, from quality closed-cell foam.
