The reason why the flight to Toronto is expensive is the Greater Toronto Airports Authority or basically the dolts that run the airport. They have high landing fees and other BS fees that they charge airliners.
I was in Buffalo three weeks ago. The airport isn't far from the border. If you have a passport, you are laughing. There is some other ID you can use but a passport is the way to go. No problems with it.
Canada Customs will ask you the purpose of the visit, the number of days staying, and whether if you have any alcohol and cigarettes. Have your passport ready before you approach the customs agent. No need to BS them.
If you hit the Canadian border on a Friday or Saturday, you will cross the border fairly quick. My best and worst times for crossing the border is 10 minutes and 1.5 hours, respectively. Coming back to the USA is always quicker.
Here is some info to help you out:
http://gocanada.about.com/od/faqscrossingtheborde1/p/border_tips.htmIf you need any other help, fire away. And I mean that figuratively. Keep your real firearms at home or you will have a problem at the border.