Great information, thanks for the detailed writeup! I am in a similar situation, younger than 59 1/2, with my workplace (that I retired from at 55) 401K and Roth 401K all at Fidelity. I am wanting to rollover $100K to a Roth this year and avoid the 10% early withdrawal penalty. I rolled over a partial amount last week into a Rollover IRA and Roth IRA. Now I want to rollover the Rollover IRA to the Roth IRA, but I'm not sure if the 10% penalty will apply. I called Fidelity today and got mixed responses. I can withdraw from my company 401K without the penalty, but now that it's in a separate Rollover IRA, I'm not confident if the penalty exclusion still applies since it's no longer in my workplace account. I plan to call back tomorrow hoping to get someone that sounds more confident. What part of your process ensures that there is no penalty? Like you, I want to have taxes withheld. I plan to ask tomorrow if rolling over directly from my workplace 401K (since I can withdraw from it without penalty) would be a cleaner process. Any insight you might have to clear up my confusion, would be appreciated. I want to go in with as much knowledge as possible. Thanks again for this thread!