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The first thing you notice when you get a hold of the Canon 40D is the big difference in its size and weight compared to the Canon 400D. The 40D is definitely heavier, but fortunately not that much bulkier. The weight difference becomes noticeable when you put the batteries in since the 40D's battery pack is heavier than that of the 400D. Likewise, the Canon 40D is larger than the 400D: 146 x 108 x 74 mm vs. 127 x 94 x 65 mm. The good news is the 40D has a better grip than the 400D, so its weight won't really bother you that much.
Design-wise, the Canon 40D definitely looks better than the 400D. When it comes to DSLR, the bigger your camera, the more robust looking it becomes. Another thing that you'd immediately notice with the Canon 40D is the different layout of some standard controls. The Power On switch for one, which was located near the shutter button of the 400D, is now located below the camera's body near the edge of the view finder. It’s just a matter of getting used to it. Another minor change is the use of the rotating navigational dial. In the Canon 400D the navigation button was a 4-way jog dial while in the Canon 40D, it’s a navigational wheel of sorts. There's also an additional button in the middle for activating the Live View Mode.