Hello AGazzaz,
I am the author of DemoRecorder so I can probably help you out with the crash of the export filter which you showed in your email.
Once the crash is fixed you can export to Flash/FLV ( as attempted with the shell-log in your post ) or to AVI, both resulting in videos which can be played back both on Linux and Windoze. (as you have asked for playback under Windoze)
( the AVI even works with the Windoze Media Player... and of course with Linux players such as gxine )
For getting the crash fixed please send me the DemoRecorder-recording called "test" in your example. I will try to reproduce the crash with this example, then fix it and make a prerelease containing the fix available for you.
( if the example "test" it is too large for sending by email please tell me and I will give you instructions for uploading. )
Since an original DemoRecorder-recording is a directory of files, please create a tarball of this directory.
Also I can probably help with with the recording sound volume. Most of the time, the mixer settings have to be adjusted. (please send me a screenshot of your current mixer settings or post it here). Sometimes the microphone signal is simply too weak for the sound card. Then a microphone preamplifier is needed between microphone and soundcard.
Best regards,
Chris