Rusty, there should be no problem with getting big knives into Canada currently or in the near future. Canada customs is interested in knives that are illegal such as push daggers, switchblades, butterfly knives, etc. Note most of these are weapons oriented and concealable. If you are crossing the border with a large knife in the car, the customs officer may give you a hard time. You may need to provide a good explaination why you are taking it into Canada.
There is no duty charges on goods made in the USA and Canada. However, Canada customs will collect a federal sales tax (GST) and provincial sales tax (PST). In Ontario it is 7% and 8% respectively, and this is applied on the CDN $ value. Also, customs or the post office charges you for the privilage of collecting the tax, in Ontario it is 5 $CDN. Note, if you are lucky and the package is not taxed (often happens for items under 100 $CDN), you also do not have to pay the 5 $CDN and get your package in a week rather than 1.5 week. A duty may apply if the country of origin for H.I. khukuri's be know.
Customs has not always inspected the large fixed blades I have imported. For example my Mega Salyan was not taxed or openned (go figure). Custom puts a sticker on the tape to show that the package has been openned by them. Every folder I have imported has been examined by customs.
Coming up to visit Rust?
Will