My friend drives from Chicago to Toronto every weekend and I drive To Toronto every other weekend. If you pass the border quickly (means no long lines to wait), it takes about 8 hours from Toronto to Chicago. My suggestion is not to avoid toll way, it is very cheap here in USA. I use I-PASS so I don't know exact how much it costs, but I saw my friend paid it in cash, I think it is under $5 toll fee totally.