@marbar here's a slightly simplified example. Consider these numbers as an illustration of how calculations work. Not what the numbers should be.
The big picture: A business that makes $200K.
Further assume $30K in itemized deductions, $20K in SE health insurance, and a 401(k) with $20K elective deferral and $25K employer match. We'll also need to adjust for the employer half of the FICA and Medicare.
The disregarded entity LLC calculates its QBI as $200K profit minus $20K SE health minus $20K elective deferral minus $25K employer share and also minus roughly $12.5K SE tax adjustment. QBI then equals $122,500. And QBI deduction
potentially equals of 20% of $122,500 QBI so roughly $24,500... But you need to look at taxable income because QBI deduction can't exceed 20% of the taxable income. That taxable income probably equals $92,500. Twenty percent of that taxable income equals roughly $18,500. Thus, that $18,500-ish deduction is what you get when the LLC treated as disregarded entity.
If you elect S corp status and pay shareholder $80K in base wages, add $20K of health insurance which counts as wages, do a $25K employer match, and pay roughly $3K in employer FICA, your QBI is roughly $72K. You get a QBI deduction equal to the LESSER of 20% of the $72K or roughly $14K... OR 20% of the roughly $102K of taxable income (the QBI plus the wages minus the elective deferral minus the itemized deductions) which means a QBI deduction of potentially $20K-ish. The QBI deduction with an S corporation is the lesser of the $14K or the $20K so you're talking a $14K QBI deduction.
But look at the delta: With the LLC treated as a disregarded entity, you get $4K more... which at 24% marginal rate saves you maybe $1K in federal income taxes. That's the incremental federal tax savings from bigger QBI.
So the $64 question at this point: How much FICA and Medicare does the S corp save with above numbers?
Well 15.3% of the interval between the $80K in base W-2 wages and the $160K FICA limit. That's roughly $12K. And then you pick up roughly another $1K in Medicare on the rest of the income. So now you're at 13K in total savings.
An S corp will push you to outsource your 1120S return and probably your 1040 too. You'll also need a real accounting system and a real payroll service like Gusto. Figure all that stuff costs $3K annually? So you maybe you're basically $9K a year ahead when you net EVERYTHING? Something like that.
Lots of the people who bash S corporations don't understand the above accounting. Which is too bad. Because the compound benefits snowball.
I did this blog post years ago to show this can be a million dollar missed opportunity:
https://evergreensmallbusiness.com/million-dollar-s-corporation-mistake/