1. In the airport, what do we tell customs about why I'm there?
2. Before we leave the US, is there anything I need to get here for the application?
3. If my application isn't approved until after 6 months have passed, do I need to leave Canada, or is it okay for me to stay?
4. My husband will not have a job right away when we get to Canada. Will he still be able to sponsor, or do we need a co-sponsor?
Hi SVL! I was in a kind of similar situation... Coming to Canada to stay with my husband but no sponsorship started yet. So, I'll try to answer according with my experiences. Hope it will help you.
1. I told at the Customs that I was here to visit my husband and meet his family, spend the Hollidays with them, and also told we were going to apply for sponsorship (outside Canada though). Since I was travelling by myself, I took with me an invitation letter, similar to the one sent to the Consulate when I applied for a visitor visa, but it was not required by the officer. He asked me a few questions and gave me 6 months to stay in Canada.
2. I brought my criminal checks from the countries and states I had lived in, documents (birth certificate, ID from my country, etc), and proofs of relationship such as e-mails, MSN chats, plane tickets from trips together... Basically everything that was missing for our application to be complete.
3. Since your husband will be going to apply for sponsorship inside Canada, I believe you will have an "implied status" and will be legal to stay in the country until your process is finished. My case is different, I am inside Canada but applied outside (already approved in Mississauga, yay!) and I will have to extend my stay in case my process is not finished until May.
4. I will pass it. Don't know the answer.
Good luck!