Our drive west began at 4am this morning (on account of the ferry schedule).
If you want to avoid Sudbury and its famous nickel next time you drive west from Toronto or environs, you can cross Lake Huron on a ferry (from Tobermory to South Baymouth). The trip is 2 hours and is not unlike the BC Ferries trip from Vancouver to the island, though the water is a lot calmer and you're in no danger of seeing any whales. Huron is still big enough that you can't see the shore at all once you're out in the middle.
Then it's not too far to Espanola, where they seem to make a lot of paper, and you can turn left onto a Trans-Canada highway (Ontario seems to have 2) and head for Sault Ste. Marie.
Distance travelled: 600km
Timmy's passed in Ontario: 10