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When I do visit the US, (with Canadian PR) do I have to fill-out an I-94 (arrival/dep record)? Does anything get stamped on my passport??
No you don\'t need to fill I-94 for visiting USA and nothing gets stamped on your passport. Being a Canadian PR and visiting USA, all you need is your passport and Canadian landed Immigration papers.
However if you want to work in USA, you need H1. You can live in Canada and still work in USA as long as you have solid proof that you actually live in Canada (rental lease, car insurance, drivers license, utility bills at your name etc.) and file annual tax return in Canada. USA and Canada have special treaty you do not have to pay double tax. Canadian Immigration does not care where you work in USA, as long as you file taxes and frequently visit Canada, and maintain residence in Canada with above mentioned proofs, Canadian Immigration people can not touch you.
If US immigration officer on border send you back to Canada due to some reason, even then it does not get stamped on your passport. However, US Immigration Officer\'s have the authority to ban your entry into USA, that power is only used if you smuggle drugs, or think you are communist and USA Immigration Department use very rare on average person.
However if US immigration officer pull you inside for questioning, they can find out everything about you, and your pending case for immigration if you have one. So how it will impact pending US Immigration case, you better take advice from a good lawyer.
USA Immigration Officer can stop you from entering USA, if he/she is not satisfied with your answers that you are visiting USA. If INS stops you from entering in to USA, this is temporary and you can try later with solid proof that your intent is to visit not work or stay for longer duration. You can try same day but on different car, as once they stop you from entering the USA they flag your car Plate. SO next time when you try they will immediately know that you was stooped before. However, this information is temporary stored in the INS database system and is available to all INS officer for 24 hours after each occurrence, or may be longer but I am sure is not permanent. So one can try on different car even on same day and still cross US border even you were stopped, but safe will be at different border crossing to avoid the same immigration officer.
When I am supposed to be out of the country for 1yr after the 6-yr limit, do the above visits constitute any violation of the 1-yr ban??? Can INS use it against my GC which in currently in process.
No your visits to US are not violations of 1-year ban. 1-year ban is on your payroll. You can not earn for one full year in USA. So if you have a proof of job in Canada and visit USA, I don\'t think INS can use this against you. US Immigration is based upon future positions. As long as you can prove to INS that you intention is to visit USA and not work or stay longer, this should be fine. Again take an advice from your lawyer in this regard.