If you are going to build a 540 BBC you will need a Bowtie, Merlin, or 502 block. THe Bore is 4.5 and the Crank must have a 4.250 stroke.
I am not an engine builder, but I have reaserched this motor combo for my boat.
You may want to call REX Marine they sell a 540 Merlin (Block & Heads) crate motor.
Brent