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In the controller, go to Music Library, then select Songs, then click on the three dots on the song you want to add to a playlist. Add the song to the "queue". Then go to the queue and/or song, and click on the three dots, and select add Song to Sonos Playlist. That will bring up a menu where you can create a new playlist, or select an older one.
Yes, the generally accepted limit is 65K, but that's just an estimate, which varies based on other metadata in the files.
A quick google search turned up this thread as a starter, but there's others: