I'd like to see this too. I've considered getting a card with video out and in but you lose a lot of quality recording PC video on VCR and then bringing it back in. Exporting film to AVI directly would be ideal. If you can take screenshots like you can in Aces High, you should be able to produce film... just take 15, 24, or 30 screenshots every second (whatever the end film framerate required) and then put em into a film--no compression needed.
I've been able to make films like this by slowing down film replay in AH and then snapping off screenshots as fast as my finger could tap Alt-S. Then I used Quicktime to import a picture sequence and make a film. It worked beautifully, but the motion was kinda herky jerky since my finger couldn't tap away at a constant time period.
I suppose you could write a macro for your joystick (say using Saitek SGE software or the like) that would automatically do this for you at an exact time, but there is a slight pause when taking a screenshot--I'm guessing due to the file being written to disk. So you'd have to slow down the film in the replay, but you can't get a precise measure of how much you've slowed down the playback so the end result would be a film that wouldn't play back at the exact speed of the game. That could be adjusted to get pretty close though.
HT could add the export to film feature in Aces High by making a loop that takes a screenshot every 1/30 of a second, or if the screenshots can't be written to disk that fast, maybe slow the film down to 1/3 speed and take screenshots every 1/10 of a second.
