What is the weight difference between a 454 and a 540ci engine? also any size difference front to back and sise to side?

If you use lighter forged parts it would be less. Aluminum exhaust, heads and intake vs cast iron. Lots of variable.

if they are both setup the same they will essentially weight the same. The outer physical dimensions of the block are the same, only the bore and stroke are different.

the only weight/size difference will be in your wallet...

Unless you go tall deck...

The 540 you will "WAIT" less to plane off

All kidding aside a 9.8 deck 540 the weight will be close and size will be the same.
Jim

If anything, a 540 reg deck should be lighter than a 454 due to less cylinder wall. Sure the crank weighs marginally more due to the longer stroke, and the pistons are slightly heavier, but the net should be lighter.

only difference is the block may be a little heaver and the crank will be a little heaver maybe 20 lbs total. For a block to go out to 4.5 bore it is going to be ether a after market block ,a bow tie block or a high nickle mk 5 or 6 502 block all of which are a little heaver then a 454 block

Good Point.