Yea, that flight would be rough. Typical sizes: depends on the movie and the settings you use. If the movie fits on a single layer disc, about 4.5 GB for a DVD folder, about 1 GB for an AVI of reasonable quality. Lots of the recent movies run 6-7 GB for the video files, around 1.5-2 GB for the AVI. If you have time to experiment some before you go, you can trick DVDFab into really crunching DVD files by setting the "Default DVD5 Size" in Common Settings-->Write to say 2500 MB. This will let plenty of movies fit on your HDD with room to spare and will have the added benefit of no A/V sync isssues and faster processing time than creating AVIs. I just tried this with Family Guy season 2 Disc 2 (7 22 minute episodes) compressed 37% and it looked great. You would want to set the DVD5 size larger for longer movies and try one and see how it looks on your system.