I'm an active contributor on the Unofficial VirtualDub Support Forums. There seem to be several questions that pop up over and over again. To avoid having to give the same answers again and again, I've deviced to write up this little FAQ list with those answers. If you have a question you think should be on here, send me some e-mail.
This question seems to be asked by far the most often... Anyway, here's how to do it:
First, make sure all your files have the same type of compression, video framerate, sound bitrate and samplerate etc. If the files don't have identical settings, VirtualDub cannot join them and you first need to convert the files so they match eachother.
Once your AVIs match, start by loading the first into VirtualDub. Then, load the second by selecting "Append AVI segment..." from the file menu. If your files are sequentally number, you dont have to repeat this step for the other files, just check the box "Autodetect additional segments by filename" and be done. If not, you'll have to repeat the append for each segment you need to add.
Now, everything should be in place. Check the video preview to make sure everything is as you want it, cut out stuff you don't need etc. If you're not applying any filters, you will probably want to set "Direct Stream Copy" in the video menu as this saves you from a lengthy recompression cycle and probably degradation in quality.
Done that? Okay, all you need to do now is save to a new file. Select "Save as AVI" from the file menu and specify a filename.
If you have one of these cards and have attempted to capture to, for instance, SVCD resolution (PAL: 480x576, NTSC: 480x480), you may experience an inordinate number of dropped frames (50% or even more is not uncommon), even though your CPU usage is acceptably low (below 80% should be fine). If this happens, try increasing the capture resolution to the maximum. On my system, I have found that capturing at 480x576, 704x576 or even 720x576 sometimes drops about 50% of frames, depending on the source material. Capturing at 768x576 (which is only available using VirtualDub's "Set custom video format" dialog), works quite well, however. I get about 10 dropped frames per hour. Resize the video after capture.
Recently, many people have been posting messages about not being able to use VirtualDub to capture full resolution video with Philips SAA713x based cards, especially under Windows XP. Especially common is error message 418. Since capture video with this combo pretty much every day, I assure you it is possible. It's not all that difficult, although it does require some small sacrifice on your part (nothing major -- you won't get blood over your keyboard and you won't need any incense or small animals): you will lose the ability to use the video overlay functionality of the board. Here's what you ought to do:
Not all of these steps are necessary in all cases, but they won't hurt.
Run the registry editor, and go to the key HKEY_LOCAL_MACHINE\SOFTWARE\Microsoft\Windows NT\CurrentVersion\Drivers32. You'll see a list of values containing FOURCC references and CODECs, such as VIDC.IYUV --> "iyuv_32.dll" and vidc.iv50 --> "ir50_32.dll". Look for any values that have no data associated with them (except the "default" value, of course). Delete those values.
Please don't. Instead, capture to a lossless format, like Huffyuv and with uncompressed audio. After you're done capturing, compress to whatever format you want. This will also allow you to do other processing, such getting rid of commercial breaks, applying filters for resizing the video and noise reduction off-line. This'll take a bit longer, but it means your final video will be of the highest possible quality.
This seems to happen with Windows XP especially (possibly other versions as well). It is caused by the little thumb-nail picture of the first frame which you see in the left-hand pane of the explorer window if you have the folder tasks enabled (this used to be called "view as web-page"). Even if you haven't enabled this, the thumb-nail is still generated. As it is being generated, Windows has the file open and therefore in use. The solution is simple: if you want the thumbnail enabled, simply wait a few seconds as it is being generated and then delete the AVI file (just try a few times). If you don't need the thumbnail, then you can disable it in the registry by clearing the Default value found at HKEY_CLASSES_ROOT\SystemFileAssociations\.avi\shellex\PropertyHandler.
If you don't feel comfortable editing the registry, you can use my read-made .REG files to either disable or re-enable the thumbnail from Windows explorer.