Thanks for the reply
@seattlecyclone , but I don't think I'm understanding.
I was not aware that I could move after-tax 401k contributions to a roth IRA without the pro-rata rule. I thought it triggered for any conversion to a roth IRA. I will look more into that. That approach doesn't work for me though, because my company plan won't let me withdraw funds from the plan while employed, but I think it may be an option for my wife.
The second item
In my company 401k, there are 3 contribution options: std 401k, money goes in pre-tax (this is where all match dollars go, as the company still doesn't offer roth 401k matches). After-tax 401k contributions, and Roth 401k contributions.
I am income limited, so can't fund a Roth IRA. I have a $1.4M standard IRA (from prior company pension/401ks), 67k in mixed roth 401k and match dollars. This year they are adding the ability to do an additional 12% after-tax 401k contribution, and then do a daily sweep to convert in-plan, from the after-tax 401k into the roth 401k. In this scenario, the IRAs never come into play as I understand it, so I don't think I have to worry about the conversions getting pro-rata mixed with the IRA. Its the tax provisions behind this that I'm trying to find and confirm. I did look up separate contracts, but that didn't get me what I was looking for, or perhaps I just wasn't smart enough to understand what I was reading.
Thanks!