Does anyone have suggestions for building non acolyte-type characters? I.E. beginning class characters such as an Empire Guardsman or other such class? Other than giving base attributes and some basic skills is there another route? I was thinking along the lines WHFRP has (not familiar with the new system, haven't played it since 2nd edition). It would be nice to have characters start out as 'normal' characters in the WH40K universe and work their way up to acolyte status or to have players working alongside acolyte-class characters. Any suggestions/guidelines?

The major difference between beginning characters generated for DH as accolytes and "normal careers" is actually pretty small overall. There is the theme and background difference that an Inquisitor or their agents have recruited the character for service to the Holy Inquisition, and then the major difference which is represented with Fate Points. There is also the relative freedom of action that Inquisition service unlocks compared to their mundane counterparts. A "typical" adept spends their entire career hunched over the same desk processing data fragments, while an Inquisitorial adept travels from planet to planet and has exciting and terrifying adventures.

Leave off the Fate Points and make minor tweaks to the starting gear and you have "generic careers". Or you could throw a few relavent skills and talents at a character sheet, as this is an equally valid GM tool.