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I changed the model in MED and re-rigged it with a very lowpoly model from one of Rincewind's contributions.
Could be worth a look or two.
Thats a great animation(I just downloaded it and watched in MED)

I think people would benefit and appreciate hugely from a tutorial about this process if you get the time. The reason is that you are able to use .bvh's which is a common file format. Some of my problems is that I can only use motek's format.

There are a larger variety of .bvh's available.

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I don't think that video capture for animations is trivial
Definitely agree. It is worth good money to pay someone who has the technical knowledge to deal with file formats, rigging and some scripting needed to get them working. In the 'real' world of game development there are specific people hired for this. Usually they are called technical directors or TD's for short and it is a highly needed position.