We only played 2 sessions of our new Dark Heresy campaign before my health issues put it on hold. But during the break I have managed to finish up a custom character sheet. I made it compatible with both Dark Heresy and Rogue Trader.
The border art, logo and background watermark are IP of Games Workshop and/or Fantasy Flight Games.
Designing character sheets is something I have always done for the campaigns I have played in. Back in grade school (and 1st edition D&D), I bought paste-up boards from a local art supply store and hacked up photocopies of "official" sheets, then used a tech-pen and straight edge to create my own character sheets.
[Edit] Here is a link to a PDF file of the character sheets. It is set up with crop marks to print on an 11" x 17 " sheet of paper so there is no white boarder (required trimming). However, there should be no issues printing this file to a standard 8.5" x 11" paper size.