Family Tree Magazine has a huge collection of downloadable forms on the company's web site. The forms include pedigree charts, research calendars, note-taking forms, deed indexes, research journal, correspondence logs, family group sheets and census extraction forms. You can see this impressive collection of forms at http://www.familytreemagazine.com/forms/download.html
Matt Misbach has an excellent collection of online, downloadable genealogy forums at http://misbach.org.
Ancestry.com has downloadable forms that are as nice looking as the commercially available forms. You can obtain a pedigree chart (called an Ancestral Chart), Research Calendar, Research Extract, Correspondence Chart, Source Summary and Family Group Sheet. You can do all of this at: http://www.ancestry.com/save/charts/ancchart.htm
FamilySearch.org has a collection of online forms, including U.S., British, Irish and Canadian census extraction forms, family group sheets, blank timelines and more. The forms are available at http://www.familysearch.org/eng/Search/RG/frameset_rhelps.asp?Page=./research/type/Form.asp&ActiveTab=Type
About.com offers a number of downloadable genealogy forms, including family tree fan charts, pedigree charts, family group sheets and relationship charts. Take a look at http://genealogy.about.com/od/free_charts/
Canadian census forms for the 1851, 1901, 1906 and 1911 Canadian censuses may be downloaded from: http://www.ancestry.com/trees/charts/canadacensus.aspx.
Similar forms for the 1841 through 1901 decennial U.K. censuses may be obtained at http://www.ancestry.com/trees/charts/ukcensus.aspx.
All of the above are available free of charge.