The EOS 400D is up against some very accomplished competition, but it gets off to a running start by being a third-generation product, with a design that has evolved over several years. Physically it is very similar to the 350D, with a lightweight and compact body made of tough polycarbonate plastic over a stainless steel chassis, although it is in fact a completely new body.
Build quality is very good, with none of the cheap and flimsy feeling of the 300D. The battery and card hatches have metal hinges, and although the port cover is a rubber plug it fits well and will keep dust at bay.