Ancestry has put US passport applications (1795-1925) on line. Good stuff. Several pages for some applications, with physical description and photo (well, the photos are sort of black blobs). One of my people had to submit an affidavit explaining why he had lived so long outside of the US, so I got the details of his employment history. Good thing they don't require that anymore, or I'd lose my citizenship.
Anyway, definitely worth looking at if you have an American ancestor who traveled overseas, although a passport wasn't required 'til WWI so some of my ancestors didn't bother to get one.