we meet the physical presence test for FEIE and our ordinary W2 income is $73k.
The calc is confused - for the FEIE calculations I need to add valid data checks and improve the summary text
Make 2 small changes to your inputs and the output will make (more) sense:
* Box 1 on your W2 should show $67k ($73k income - $6k 401k contribution.) Put this in the ordinary income box
* On your 1040 you won't have any Adjustments - change adjustments to $0
Based on the above (attached) you can Roth convert up to the full amount of the standard deduction ($24,800). If you do so, you could also harvest up to $13k in long-term capital gains. Or do no Roth conversions and harvest up to $37,800. Or some other combination <= $37.8k.
One thing worth noting:
Making traditional 401k contributions in this scenario is not tax efficient - you are trading a 0% tax rate now (via exclusion) for an unknown (but most likely higher) future tax rate on withdrawals. You get no tax benefit now, but have all the tax consequences later.
If you can, changing your 401k contributions to Roth would help you win on both ends.
Caveat: if you have no Roth option and get a healthy employer match, then it is probably still worth contributing (e.g. you get a 50% match, which is better than the max 37% marginal tax rate.)