You were all correct—customs was a ton of drama at the airport . I was pulled into the back for an interview, starting with one agent, then two, three, and finally four, including the supervisor. They were baffled about why my visa hadn’t been canceled, as I never activated it before its expiration and why it was listed as "in production." The boss asked, "So are you going to reapply for a visa?" Before I could respond, another officer jumped in, "It’s in production and already in the mail." The supervisor walked away, looking confused. The agent informed me that I’m considered a visitor until my green card arrives and advised me not to remain in the US until it does. They emphasized that my case is unprecedented but assured me everything is on track. Clearly I failed to get it activated as everyone said here.