After making 50 or so movies, I have decided that manually is DEFINATELY not the way to go 
Even if you ignore the time and frustration of doing it manually, there is the much bigger concern that I have that running the same game from different versions is going to create a slightly different loop. I believe the best way to go would be to improve the loop detection and possibly adding some kind of hinting system.
For example, rather than absolute frames, if a correct loop could be detected by changing the min and max settings, etc. then record those...
Seems like to be the consensus - it also seems that the loop detection currently does rather well. We can build a database automatically from this, then as people work through them make changes manually. Once 1 person has done it, everyone can then do it first time....
Also, there HAS to be a way to create much smaller .AVI files without sacrificing quality??? Some codec that takes into account limited colors being used or something? How much affect does using cartoon mode on XVid, etc. ?
Havn't thought about this for a while. Forgot about it once it was all up and working.... Because of the annoying way that virtualdub sends config data to the encoder, settings have to be hard coded (ie Buddabing can't just add an option to let you set any bitrate).
Currently Xvid is configured to do a "quality based" encode. That means that it alters the bitrate as required to keep to the quality at a certain level. This is the best way of encoding a bunch of very different videos - eg if we had a fixed bitrate it would probably be hopelessy over-the-top for something lo-res like missle command, but make really ugly videos for something complex and hi-res like coolboarders.
The current "quality level" is generous and it makes (IMHO) high quality videos (You can play them back full-screen, and they look good). Its possible to alter the setting, or perhaps add "options" like low/medium/high quality but it would mean more work and some ugly copying/pasting for Buddabing. Not sure what he feels - if he agrees then I can try out a few settings and post him the changes.
However, if you wish as a workaround you can compress them however you want: set the movievideo option to 0 (no compression) and then you can use Virtualdub to recompress this using whatever video codec you like. Note the uncompressed videos will be *massive* until you compress them.
NB you could also try using the DivX (movievideo=1) or cinepak (movievideo=2) options. I do not know what settings the divx is set to. I would suggest that the cinepak is of a much lower quality, and therefore maybe smaller.
Also - is it the overall size of so many videos that is too big, or are there particular files that are much bigger? Could you list them if so?