Right now i'm at 630 days in (1,200 out) and my PR expired on April 17th 2024. By the time I leave for the states (1st week of June), I'll be at ~680 days. So i'll need ~50 days to hit 730 days before I can renew. That's why the talk around back and forth between Vancouver and Seattle.
Are you saying all these plans are irrelevant if i haven't hit the target before my PR expiry?
If you are in compliance, you can enter and leave with an expired card with no issues, apart from possibly some tedium at secondary while they pull up your information and check.
But if you're not in compliance, every examination (eg every time you present at port of entry) increases chances of some issue. And yes, they could go so far as to 'report' you for being out of compliance, which would make things quite complicated and potentially lead to revocation of PR status (perhaps unlikely, but the process would still likely be unpleasant).
Now, with 680 days and being settled (it seems) in Canada, then perhaps they'd not do that. But they might also put you on secondary exam list (every time you get the full examination), or warn you, etc. And you might get one in a bad mood who decides to make things difficult or whatever. Consequences could be lengthy, eg getting off the secondary exam list might take years.
Far, far better - in my opinion - is to delay your switch to working out of USA office for a couple or three months and then apply for the PR card when in compliance, and only then start travelling to USA. It will really make a big difference for you in terms of being able to cross with an expired card (while waiting for the card), getting the card renewed relatively quickly, etc. Most of all - if you're in compliance - effectively no risk at each interaction.
If you can't do that, then delaying it or minimizing trips (every second or third week?) until you're in compliance would still be an improvement and lower the risk.