Dave61

We eventually did get this sorted via trip and the USCIS Houston office, after multiple further visits to the DHS deferred inspection unit at Bush airport facility in Lee Rd. The K2 was finally removed from paroled entry and admitted as a k2 in July. AOS was immediately filed 5 months after my wife's AOS went in. Chicago sent his 797 a couple of weeks later, and a week after that his bio appointment 6 weeks after my wife did her bio, he received another letter 1 week after doing his bio requesting further evidence, submitted next day and confirmed received a week later by mail, that was about 3 weeks ago. My wife was requested to attend appointment - wait for it for I-130 we went, we did and have heard nothing since for the last month. Now on the web site the boy is 2 buttons ahead of the mother in terms of progress status. It is now Mid September 7 month after submitting her 130 and over 5 months since submitting her 485. We understand from your support the 130 was not needed, and we did not do a 130 for the boy and he had is 797 in hand really fast after his 485 was sent. A mystery from beginning to end, and still we wait and wonder. Maybe we should have done this AOS through an attorney, but in real terms wasted our money using an attorney through the 129 stages as we did all the work on that front anyhow. Once this progresses to completion I will make another post, hopefully in the not to distant future. BTW the fact that my wife can't get a driving license until her green card is in hand is nothing short of astonishing, she arrived 12/29/2011 and is stuck in the house. The land of the free! Mmmmmmm

Tip number one. stop listening to the CBP people. They know little to nothing about immigration.
Your wife arrived on a k-1, if you married within the 90 days you are ok to file the I-485 along with other things (follow the guide) and adjust status for her even if the I-94 is expired. I don't know why they said to submit her paperwork at the infopass appointment as it has to be mailed to the Chicago lock box to be processed. I don't think they will accept it at the local office (maybe call and check?)
Sounds like maybe you didn't state the son would be a follow-to-join so the consulate put all the paperwork in one envelope thinking they would arrive together. Of course you would have no way of knowing this since you can't open the envelope.
Sounds like the only problem is tracking down the son's paperwork and I am willing to bet it is all in the one envelope but who knows where that ends up after entry. My best guess is try to get a copy of what was in the son's brown envelope sent from the consulate to the appropriate authority here in the US or else track down the original brown envelope and see if his paperwork is in it. How you could go about doing this I don't know but this is the main issue.
Despite this your wife is here with no status (after the I-94 expires)until you file for her to adjust status. Highly unlikely she will be deported. The son is in limbo until his paperwork is found, but this is not your nor your family's fault...The US government has messed up yet again.