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Hi Stefan,
6.5GB sounds right for a 40-sec video at hi-res. After you process your vid in Registax or AviStack or AutoStakkert or whatever and end up with a stacked image that you're satisfied with, you can compress your avi video file with a standard file compressor (zip, rar, etc.) and burn it off to a CD or DVD for archiving. Then delete the compressed file from your hard drive to make room for the next video.
You don't want to use a "lossy" codec to compress your video as you're acquiring it. You'll get a smaller file, but at the cost of lost detail in your image. You might try RGB24 rather than RGB32 and compare the results to see if you get a smaller file with no loss of detail.
Hope this helps.
Anders
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