multisegment capture causes vdub to crash

Were you able to capture in multiple segments before the fresh install? Have you tried deleting all of VirtualDub's registry settings? Also, I don't have XP, but a friend told me that you don't need to use multisegment capture with XP & NTFS. He regularly captures 10+ GB files with no problems.

My buddy said his captures are fine, so I guess VirtualDub is capturing in OpenDML format. Yes, I know that even OpenDML isn't meant to support files that large, but he swears it works OK.

OpenDML AVIs have no filesize limitation. You can easily capture a 100GB file with VDub + NTFS