Also, make sure you bring a letter from your chief pilot on company letterhead, detailing your need for a passport in the near future to travel internationally.
Your Airline ID will not be good enough (at least in ORD and PHL)
I renewed mine in Feb and had my new passport in about 5 days after I sent it off. Just normal processing. I thought when it showed up in the mail it was my old passport. I had Scheduling reassign me to a domestic overnight for one sequence while it was in process.
Due to an accidental washing of my passport I replaced it the same day. I'm in Detroit so Chicago was logical but it was way too booked up (the busiest one I'm told). So I jumpseated into Reagan, and took a cab to the passport office. You do the paperwork in the morning (about 30 min wait for me) than after getting your pickup time you go eat, walk around etc. Total time for me was about 6 hours until I had my new passport in hand.
For the 'letter', just show them anything that you are an airline pilot (ID was fine for me, but they also said offer letter, manual, whatever. They really don't care). Fee was about $160 total though.
I guess it depends on the office/person you get. But in ORD, my ID was not acceptable. Even with a copy of my schedule saying I was going to Canada the next week.
I had to call my Chief Pilot and then walk to a copy shop, get their fax number and get a fax sent to me there. They wouldnt even let me fax the letter to their office. Total pain.
IMO it's not worth the hassle of going to another city to sort out the renewal. At Mesaba we just tell scheduling and they put us on the Canada no fly list. Problem solved until the passport comes back, then you get off the list and can go back to Canada.
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