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How did you tweak the settings? The options seem very limited. Is there a file size or resolution size option somewhere in Fraps?Hypercam is alright for a free one, I recommend Fraps, best quality for me.
It really depends if you know how to set the settings right, and know how to upload it right. Fraps was really bad quality for me until I tweaked with the settings a bit and it came out beautiful.