“HandBrake is a GPL-licensed, multiplatform, multithreaded video transcoder. It converts video from nearly any format to a handful of modern ones—that’s it.” — So I don’t think you’re gonna be able to use it to slice up your videos into more manageable chunks. That said, part of the problem you’re describing is that you’ve apparently asked Handbrake to save your video to some virtually lossless codec… and that’s why the filesize is increasing so much. There are some builtin presets you can select from as an output format. I’m generally happy with the “iPhone & iPod touch” preset which keeps the destination screen size small (good for YouTube) and employs a very efficient compression, m4v. — Sorry, I’ve never tried VirtualDub. If it were me, I’d likely end up using iMovie to do the segmentation work. But there are plenty of alternatives, like this.