U.S. embassy in Bangkok used to do it while you wait. You now have to make an appointment in advance (not hard to get). While it used to be free, they now charge the same or pretty close to the cost of a new passport.

Expect many U.S. embassies abroad are the same. Suggest you call the embassy where you are and ask.

Having it done in the States would be a major pain.

Good thought - but will both passports work with global entry / APEC card / etc....

Thanks - will check if I can get this done in Helsinki this week! I just emailed them - let's hope they can manage it!

I haven't tried that, but one would probably be traveling with both passports most of the time, maybe more than 90% of the time. Being able to travel without the benefit of global entry / APEC / etc. seems better than not having the option to travel at all while waiting to get one's only passport back.

Nope, and they effectively expire 18-months after issuance due to many countries requiring 6-months validity at the time of entry.

Yes - I learned this the hard way last year and got much abuse here for that lol. Yes I travel more than 99% of folks but I seem to constantly miss all of these little rules even though yes I know its my responsibility! On most trips I am in four or five countries.... For example - on my trip last week to Slovenia I was in Germany, Austria, Slovenia, Italy, and Croatia - in four days and most of it driving (except for Germany). A typical Asia trip for me is Japan, HK, China, Indonesia, Singapore, Korea and Thailand. I guess I better bookmark the state department website from now on...

Following up on the ABTC and Global Entry issues on a second passport, it shouldn't work with ABTC since the passport details on the card are supposed to match what is in the passport that is presented.

But I checked Global Entry and there is space for three passports and one of mine was a second passport that I used to have so it appears you can have a second passport added and use Global Entry. Assume you have to go into the Global Entry office to have them enter the second passport information.

Thanks for checking on that!

On my previous PP, which was getting full, the Japanese PP control agent, pasted the entry "sticker" over old PP stamps. In any event (looking at my current PP), Japan used only 1/4 of a page,][Their "stickers" are small.]

The cost for extra pages is $ 82 . It is added in packets of 24 pages with max of 3 packets so make sure to ask if they can add 3 packets (same price $ 82). I know embassy in SIN does it in a day or two but will only add 2 packets.
I just read that US gov. is getting rid of this service by Dec.31, 2015!
If you are near PHL you can get a new passport on the same day at the Passport agency for extra $ 60, just need an appointment and remember to request the 52 pages version. I don't know about other locations.
My Indian friends tell me they just rubber band old and new passport together when they travel on visas. Hope that is possible especially when one has $ 150 visa valid for 7 more years in the old passport.