I hope I am helpful.
The encoding thing may sound complex, but it really isn't.
I think recording at full size would be better. Should still be viewable.
Here is some information with FRAPS and what-not.
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After recording the video files with Fraps, the next step would be exactly what?
Can I put two video files togheter on Virtual Dub or the program just re-encode a single video file?
If you don't have anything to edit out, there is a AVS script that allows you to put in the video parts one after another and then do the encoding thing.
AviSource("file01.avi")+\
AviSource("file02.avi")+\
AviSource("file03.avi")
Just replace "file01.avi" with the directory to your video file. If you have multiple ones, you have to do it for all the other parts as well. It's not that bad.
If you need to "edit" out, you can use VirtualDub. That is what I use. I then save it using ffdshow codec. There is also an AVS script that can "cut" parts out a la VirtualDub. You have to figure out the frames to "cut" though. =/ VirtualDub helps, even if MeGUI has a video preview (VirtualDub is faster for searching.) The AVS Cutter in MeGUI is located under Tools.
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What's the average size for the videos after they're re-encoded with virtual dub? And on the final merge?
Depends on the codec for VirtualDub. As for the merge, it will usually be MUCH less. Size is determined by the settings when using x264 thing. To give you an idea: I did a Heavenly Guardian Longplay. The original recording was 32GB for 2 hours and 30 minutes. Re-encode with VirtualDub (to "edit" out mistakes) and came out to 50GB. After doing all the merging and stuff, it came out to 600-somethingMB (how I got a 1GB file when I uploaded it on my channel, I do not know).