Hi, sorry for being quite but full time job and 2 kids keep me way to busy. The BB was sealed within 3 days from taking it home. The mfg instructions says to do it right away, which I did. I did not screw it to the island yet because I was sealing it several time. Yes t was in warranty but to rent a track to bring it back, ask the cabinet maker to cut to size a new piece, would cost me the same. Also, the pieces are moving and it is not as flat as the 2 pieces we bought 3 years ago. I actually kind of neglect those in the basement (only BB oil twice at the very beginning and that was it) and they look fine. I have seen other IKEA products going down the hill. They want to give price reduction against very poor quality (for instance cabinets knobs and handles). I have been a IKEA Customer for 20 years so I can really see the trend.

The two (interesting shapes & ikea butcherblock) are not mutually exclusive. We plan to buy two lengths of ikea butcherblock, cut an edge off of each and glue the two together to create one super slab. Taking that and cutting a bow shape would be quite do-able if you are handy. I might even suggest practicing on a sheet of plywood and then using that as a guide (clamped to your butcherblock) for the final.

I think you'd need 25" so as to have a bit of overhang, but kitchens do vary. Red oak itself should be a fine material, but not knowing how the one at Menard's is assembled, I can't say if it would work. If you can order a one-foot section and test it out a bunch before the big leap, it could be worth doing.

I hadn't thought about using the filler to hide uneven walls. That's for that heads up Sophie! I actually have about 3.5 inches extra on that run and am trying to figure out where to put the filler, so adding some between the fridge and the wall won't be an issue. I guess I won't be able to put a refrigerator cover panel against that wall though, for the same reason you mentioned.