Rabbidgerbal’s Super Simple 1PG Sci-fi Skermish Rules is a set of free wargames rules meant as a 40K replacement.
Yes, that’s really how the author spelled “Skirmish”
Warhammer 40K variant
One Page 40K Rules
One Page 40K Rules are a set of simple rules for the 40K Universe. The authors write:
One Page 40k is a single-page ruleset designed to be fast to learn and simple to play. It serves as a great introduction to the Warhammer 40.000 universe for people who are new to the game, and as a way to play quick games for veterans of the franchise.
Warhammer American Civil War Variant
The Cops.NU site has a Warhammer 40K variant for the American Civil War. I think it could work.
Warhammer Colonials!
These aren’t exactly free wargames rules, but if you already own a set of Warhammer 40K, this is worth checking out. Jervis Johnson has provided this page of colonial amendments to Warhammer 40K. These also would be a good way to introduce fantasy and science fiction wargamers to historical miniatures games.
Imperial Guards Vs Zombies Rules
Imperial Guard vs Zombies is a set of modifications for Warhammer 40K