OK, so I realized I was using my total income instead of my taxable income after exemptions. So if standard personal exemption for a couple filing jointly is $11,900, and I up my 401(k) contributions to 25% through the end of the year:
$84,000 total regular income
-$11,900 standard married-joint exemption
-2 * $3,800 = $7,600 personal deductions (I do get to take both of these right?)
-6% * ($52,000/yr work income) * (5 months/12 months) = $1,300 401(k) contribution deduction
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= $64,200 taxable income!
Which avoids bumping me into the 25% bracket by several grand. I also plan to increase my 401(k) contribution anyway, probably to 20%, which would bring my taxable income down to ~$62K for the year.
So assuming that all goes according to plan, we should have enough breathing room to go ahead and move that money to Vanguard without a tax penalty, taking advantage of the soon-to-end 0% capital gains loophole and save a couple hundred bucks. :-)
Is there anything obviously wrong with my math here?