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Well, I've been GMing a Dark Heresy game recently, and the players have managed to get themselves into bigger stakes than I expected. Large enough that I want to do some mass combat. Problem is, rather than use the built in rules for Mass Combat, I think it'd be more fun to play it out in a game of 40K. The problem is statting my players' Acolytes on the tabletop. Does anyone have a system to do this?

We have two Psykers, a Tech Priest, A Cleric, an Assassin, a Scum, and Two Guardsmen.

I would suggest having a look at the GK codex, at the Henchmen section. That should give you an idea of what an Inquisitors retinue class will look like.

You're better off going for a skirmish level than full on mass-battle.

The problem is huge percentile ranges dwindle to the same relative stat with a d6 system as all humans are more or less the same in 40k.

Have a look at Inquisitor in specialist games. Bigger scale miniatures, but much better at capturing what you want

Probably easier to convert DH to Inquisitor anyway.

Would give a more true conversion, and still allow most regular 40k terrain (even at 54mm - the CoD ruins are designed for it as well). At 28mm, even easier, just halve the distance scale (it uses yards and commonly 1"=1 yd. Go to 1/2" per yard and it scales better.

In 40k rules your acolytes will die horrible. Any goon shooting a lasgun will have about a 1/6 chance of taking out a basic acolyte.

Anyway, the codexes you want are Witch Hunters, the old Daemonhunters, and the new Grey Knights.

Try looking at the Horde Rules from Deathwatch. That should do the trick nicely. More detail on them in Mark of the Xenos, too.