We are back
We ended up applying for the SSN card, passport and birth report all at once since the consulate is a 6 hour drive for us.
In total it took about 30 minutes. We basically just gave the women a big stack of paperwork, passport photos, the money for the applications, and she looked through it to make sure she had everything she needed, made photocopies, told us how cute our DS was.. then we signed the passport and birth certificate documents in front of the consulate. There was no interview and everyone was very friendly and nice. She spent the most time explaining to us how the dual citizenship works for him and when to use what passports..
They asked nothing about our intention to immigrate to the US (I was worried about the immigration aspect since my DH isn't US and we have no intention of moving back, I had heard him not having a green card could be an issue-- it wasn't). I had also heard that having your DH/DW be non-US and you being US could cause some sort of problems but they seemed to care less and asked nothing about any of it. All they cared about was that we filled things out right and that DS had his eyes open in his photos
Once the women was sure they had all our paperwork she smiled and said expect to have everything in about a week.. so I am hoping this means DS is 'approved'
Overall it was a painless and fast process (so far) at least compared to getting his EU stuff (which took much much longer and many more appointments).