I am sorry to hear of your issues. I guess because we travel to the US all the time we have learned the best ways. There are times when it has cost us. We did however ship to the US for $300 - $400 to FLR. I know a team shipped from Mississauga to, I believe, SVR and it was done on a next day for about $600.00. All in Canadian money. Any team wishing to come to Canada should contact Vance Scott. You can find contact info at
http://www.firstroboticscanada.org/contact.php
We love to have US teams and really any teams that would like to attend, have a good experience in Canada. If you ask other US teams that have come you also may be able to pick up pointers. Team 48 I believe has come every year, I am sure that they could help.
I have just talked to Vance and we will try to email all non Canadian teams with shipping helpers when they sign up for future events.