Closed open polysurface which openings dont have closed, planar loops of edges

BooleanUnion worked for me to create a single closed polysurface from the two objects in 4,

You can have two closed polysurfaces which happen to touch along a line or curve, but you can not combine them into a single closed polysurface. Move the surfaces so that they overlap by a small amount and you can create a single closed polysurface.