Find the German Consulate closest to you. Do this through the German Mission in the United States website, or by calling the German Embassy at 202-471-5529.
Download the German passport application form from Germany.info or acquire one from your local German Consulate.
Fill out the application form thoroughly in pen.
Have a sheet of passport photos taken. It's never a bad thing to have too many of these.
Send your application form, along with passport photos and proof of German nationality, to your local consulate. Passports for those under the age of 24 run $78 in 2010. For those over 24, the fee is $110.
If the passport you are replacing is more than six years old, you will need to apply for the new passport in person. German law now stipulates that the fingerprints of passport holders must be stored on a chip inside the passport. New passport applicants must be fingerprinted in person at the German Consulate.
If you are unable to pick your passport up at the consulate, include a self-addressed envelope large enough to accommodate a passport and $19 for mailing fees.
If you are picking up your supplemental passport at the German Consulate, head down to retrieve upon receipt of a phone call from the Consulate.