Once my son found his passport had expired the day before he was to leave for Mexico for a bachelor party. He found an early appt online in Philadelphia and he took an Amtrak from NYC to get to the office. His train was delayed so he was late for his appointed time. However, when he explained his predicament that his flight was leaving Philadelphia in less than 2 hours, they issued him a brand new passport (his had his photo ready already) within half an hour. Of course he was charged for expedition but it was done and he made his flight.