I have heard xheader and gimp are good, although I have used neither (love my Photoshop). Don't underestimate the power of a professionally designed banner, though; even the best tools are limited if the creator has no design sense (not saying you don't). Although the graphics of a site aren't the most important thing, they are probably the first thing people will see, and I know the quality or lack thereof influences me greatly as to whether I view that site as authoritative and trustworthy.
You can get a decent header designed for $20-$30, but if you don't have the cash, I recommend bartering with someone who does good graphics by offering some skill of yours for their site.
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