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If I wanted to run veterans and CCS with carapce armour in a tournament would I have to actually have stormtrooper-esque models?
I don't really want to make an entire army of carapace models as that would be somewhat expensive...also would have to make carapace advisors. An astropath in carapace armour would look...strange. Although technically he already has flak armour, as well as a laspistol, neither of which are featured on the model lol.

Probably not...
I mean.
If they all have Carapace armour all you have to do is tell your opponent. You wouldn't have to mark them out since they all have it...
Ask the Organisers to be sure though because things like this can vary from tournie to tournie...

They have flak armour, not carapace armour. Carapace armour is stormtroopers:

Yeah i get what you mean.
But if your entire army all have carapace armour then you don't need to mark it out.
If it was 1 or 2 squads then yeah you would but it isn't, so you don't...
See whta i mean?

Obviously amongst friends it wouldn't be an issue (we have been known to use milk boxes as chimeras on several occasions), and to almost everyone in a casual environment it's cool, but in a tournament with a random stranger would it be an issue? What about if it was a GW store?

At a GW store?
Probably not as long as you told your opponent and they were cool.
At a tournament?
Might not be okay. Best to ask the organisers about it since many organisers insist on WYSWIG. If you are allowed make sure your opponent knows about it.