Kermit,
Parts were captured using Fraps (
http://www.fraps.com).
Game film video was exported to AVI using Indeo Video 4.5 Set to 100%, not the default 85%.
I used Pinnacle Studio 8.1 for the editing and to re-assemble the in game audio (you may know that the games film viewer doesn't export audio to AVI).
To get that game audio I watched the film in the viewer with a audio out going to my other computer which was running sound recorder. After I had that I re-synced the audio in Pinnacle. Since the game also doesn't capture your guns and engine (although it captures everyone elses - weird) I had to go into the game and capture some audio - This was done in offline mode again with the audio feeding to another computer..
The final render was done using Indeo 5.1 from Microsoft Movie Maker at 800x600 so it wouldn't be like looking at a postage stamp. Movie maker does very nice compression, so the size worked out.
Thanks again everyone for the compliments!