@chai2,
I'm almost 100% certain the entire amount can be drawn out at once, and without penalty. And you're right, it is taxable at the ordinary income rate. Possibly, this years tax rate will be better than next year's.
If there were otherwise advantages to being Married Filing Separately, he might, separately, be able to slick it out without paying taxes, but it would have to be an almost unique situation to make that catagory pay out.