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I've got an Ascension-level Tech Priest with Trade (Right +10 and Tech Use +30. Can he build a dreadnought chassis and if so, how do I represent the challenges involved?

Unlikely. Dreadnought's are the kinda thing Marine Chapters recover from the battlefield and restore. We're talking massive levels of ancient unknown technology that they can only create by rote. And I doubt one Tech-Priest could do it alone either.

Haha don't worry with the disclaimer, I gotcha.

Hmmm...

I suggested to him earlier that he steal one (there are the remnants of a depleted SM company hiding out in his base already) but he's set on constructing one from scratch. Could he do it with the help of other tech-priests and archmagi?

Very much agree with HBMC. Building a dready from scratch is very likely beyond the capacity of anyone outside of a dedicated team of master tech adepts on a some or another more notable Forge World.

Agreed. Why not make a mini adventure arc of trying to track a lost one down? The acolytes could go looking for past sites of major space marine battles or go around a subsector looking for archives that might have information of places dreadnoughts were lost. Then you have the task of getting the manpower, skills and equipment/materials to restore it to it's former glory. And not die in the process of retrieving it.

Sounds like a plan!