I got my interim OPT card from INS San Antonio office last Friday. No
appointment needed. You only need to bring the original OPT application
receipt and your passport. Wait in the line for half an hour. Just tell them
that your EAD is overdue. Then they will give you a form to fill out. Wait
another hour and they will call you name to take a picture, then the card will
be given to you. No fee is charged. The card is good for 3 months. So you can
use it to start work while waiting for the formal