Thanks all- Your advice is excellent.
72(t) and Roth Pipeline: Excellent - thank you very much. We will definitely do the 20k pipeline when the time comes...and possible the 72(t).
Medical out-of-pocket, dental expenses, glasses, new roof, new cars: Yes, and that brings it to 50k. I've had a few minor surgeries - it adds up even with good insurance. We just had the roof replaced a couple months ago, so we're solid there. By the time we need a new car 10 years will have passed (I am hoping).
Travel: We've done embarrassingly little of this. Yes, we have plans, but most of them start very close by. We live in a beautiful country. We will budget for this as well.
Working for 10/hr in retirement: We're both in IT. We can do better than $10 :), but we can't seem to get less than 50 hrs a week. We'll see how my wife feels in a few years.
Have the wife retire and spend a year on my income working on expenses: This is now the plan. Part of her retirement "job" will be to reduce our expenses further- we're already fairly aggressive in this regard, but there is always room for improvement. We are discussing selling one of the cars.
Again, my thanks to all of you. I'll post again in a few months seeking more advice I am sure - probably advice on cutting expenses.
Regards,
Pex