We figure then wouldn't it make more sense to wait to convert any funds to a Roth IRA once we retire, so we'd be taxed at the lower tax rate when we no longer work vs at our high rate now for a conversion? It's not clear if there are conversion limits to us.
It depends on what you think your tax rates would be at the time you might take the later conversion and when you're actually taking distributions. That involves considering both your future income and distributions to determine which bracket you fall into and what the actual tax brackets will be in the future.
My personal guess is that the tax rates will go much higher for above average incomes and might even increase a bit for modest incomes, depending on the US debt situation. Looking at taxes historically, brackets have been much, much higher for most tax payers.
You're presently in the 33% bracket, what will your taxable income be during retirement? If it's going to be low, say $50k, a traditional 401k/IRA will probably be best as your taxes will be near 0 after the standard deduction. If you expect it will be just a bracket below at 28%, say you're earning $300k today and expect to have $150k in taxable income during retirement, it's much more questionable. It's only a small difference in tax rates and rates could increase a lot in the future. An early Roth conversion will also make your tax situation much more predictable and could make retirement planning easier. Even if a conversion to a Roth turns out not to be in your favor, it will still give you peace of mind in not being so concerned during debates about tax increases.
This of course assumes that if you keep a traditional IRA/401k you will also invest the taxes you don't have to pay from the IRA contributions into taxable savings accounts. If you're going to be spending your tax savings, the Roth IRA is going to be way better!
There are no conversion limits. To this.