Michael Curtis over at the Society of Torch, Pole and Rope recently posted on a nifty little program that can turn your own handwriting into a usable font for your computer, making those little kustom details on your handouts that much easier to tweak to satisfaction.
In that regard, I'd like to share a dirty little secret: I've never used custom fonts for my handouts. Or, indeed, much of anything. As a rather fresh GM, I have primarily run Dark Heresy, a system built on the old Warhammer Fantasy Roleplay rules but set in the universe of Warhammer 40,000. In that setting, I've personally gotten very good results simply typing up my documents in Notepad, which gives a very retro-technological, bureaucratic, somewhat clunky feel to the text. I started using it as much out of convenience and lack of a proper word processor on my computer as anything else, but later I started receiving compliments from my players on the quality of the handouts, specifically the font.
So, there you have my dirty, little secret: Notepad. It makes a pretty fine Imperial font - simple, free, and preinstalled. Just watch the spacing; line wrap-arounds aren't pretty.