I think that one of the main problems you are having with reading the Google Keyword tool, is that you keep looking at it as a certain % full. If one keyword looks like it is 33% full and the other looks like it is 66% full, that in no way means that the second is going to have exactly twice the searches. It may have much more.
Rather than thinking of the bars as being a certain percent filled, think of them as having notches. 1 notch is minimal traffic. 2 notches is slightly more traffic, and so on. The bar is not supposed to be filled to the exact portion of a full bar that the traffic is, but is supposed to be filled to the closest notch on the bar. If it has 1 notch it might have under 50 searches, if it has 2 notches it might have under 100, 3 nothced under 200. These are just guesses, but you get the drift. One thing to keep in mind, is that a full bar could be 10,000 searches or 100,000 searches. A full bar seems to be "over a certain number of searches". If a full bar is 10,000, then 25% would be 2,500, if it is 100,000, then a 25% would be 25,000. Therefore, the bar can't be filled to a percentage of the total, but rather just a "level of searches".
If a keyword has anything filled in the bar, that is an indication of minimal traffic. Anything past the minimum, you have to just use trial and error, and see how much traffic you get from a 50% full bar, or a 33% full bar.