You should be OK. Bring as much photo ID as you can along with the expired Passport as it can still be used for scanning purposes.
Be ready to get a lengthy lecture... Not from the border agent but from your wife
As for coming back, as a Canadian you can still enter the US with a photo government issued cards like Driver License.
Its always at the discretion of the agent. I did it with this plate on my other car
Of course I had to explain why. Always carry the Car business card
Bon Voyage
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Who Will Live... Will See
83 911 Production Cab #10, Slightly Modified: Unslanted, 3.2, PMO EFI, TECgt, CE 911 CAM Sync / Pulley / Wires, SSI, Dansk Sport 2/2, 17" Euromeister, CKO GT3 Seats,
Going SOK Super Charger