Okay, a bit more comparisons here.
First, I put velours on both headphones, followed by alcantara on both.
Here's a rundown: (velour, alcantara)
Comfort: SRH1840 = SRH1840 > SRH1540 >> SRH1540
Fit: SRH1840 = SRH1840 >> SRH1540 >>>>>>>>>>>>>>>>>>SRH1540
Sound: SRH1840 > SRH1540 >SRH1540 >>> SRH1840
Couple observations:
SRH1840 simply fits better and is also more comfortable. The SRH1540 does indeed have a different shape and it creates an awkward angling for bigger heads.
The SRH1540 was absolutely NOT intended to be used with velours! The fit was beyond abysmal. The SRH1540 is dependent on the tall alcantara pads.
I really love the SRH1840s sound, but when listening to the SRH1540 for awhile, I find it really hard to go back to the SRH1840's thinner sound.
Both cables feel (and behave) really cheap, but the SRH1840s is better. It's thinner, easier to manage, and doesn't have the massive cable splitter.
I'll have to label the SRH1840 as one of my very favorite open headphones, and the same for the SRH1540 in the closed segment... possibly my favorite.
$500 is still a hard sell for both.