Okay, I looked around and it seems there is almost nothing to copy Hulu any more. Almost nothing works. I tested much software.
So what I did is I setup my proxy service (As users in South Africa are not allowed access to Hulu) so I could stream Hulu in Firefox. I then run the episode at full screen recording with FRAPS (half size and 30fps). However, even a short episode like The Daily Show (25min or so), got recorded at 6GB worth of files with Fraps. http://www.fraps.com/ (also available on the pirate bay if you can not afford it).
When fraps copies it has a max file size of 4GB. So multiple files are created. Virtualdub binds them together and then converts them into an Xvid of around 120mb.
However, saying all that, its probably easier and faster to download the series torrent directly from The Pirate Bay.
Thats the best I can do When I watch Hulu through my proxy on a 4mb ISDSL uncapped account I do not really have buffer problems.