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WOW! I think I finally have it, but what did I do???
Been using CS2.5 to produce recordings of my narrated powerpoint presentations, so my students can review lectures online. Unfortunately, since switching from a P4 machine to one with Core 2 Quad proc,the file sizes have been growing tremendously large and a 1-hour lecture (1024/768 fullscreen with narration) was larger than 2 gig and, therefore, CS has been unable to save the file (I read about the 2GB ceiling on avi sizes, think that's what has happened).
Today I tried something new. Not sure what I did exactly, but it is cooking now :)
1. went back to good old CS2.0
2. configured my monitor #1 to the onboard video rather than my groovy dual mon PCI-e board. Don't know if this effected anything, sizewise, but did it just for kicks
3. changed the video codec to fddshow h.264. was using the CS codec previously
4. changed the microphone audio quality to mono 8-bit 11K (was CD quality stereo before) .. I think this probably made the most difference
5. even added a video camera annotation window with a talking head. Camera window sits in the top right corner and shows me in lecture.
Well, an hour-long lecture today (played it back and it isquite good video quality I might add) was recorded in only a 95 MB file. Unbelievable!!! Went from over 2GB to 95MB by making these changes. And this includes my camera window too (which I have not been able to do)!! Even shows my smartboard annotations during lecture. everything seems to be in sync (audio/video). And my quad core CPU temps seem to be staying about 10 deg C cooler than they were before! Crunch time for an hour production is now just a very few minutes. All is well with the world. I can hardly wait to convert them to FLV and start posting on our classroom server :)
Well, I solved my problem but I don't know how exactly. Guess I should not question it, just go for it. Anyone have any idea what I actually did???