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If i bought the regular box for the chaos chariot what parts would i need to build a second off of the remaining parts? From what it looks like i would need the chassis, riders, and wheels. Is that about it?

Yep, assuming you want a gorebeast and a regular chariot. The yolk that carries the horses you don't need for the Gorebeast, but the two chains that attach to the Gorebeast's ears are the same that attach to a metal loop on the horses back. So if you could get that with the marauder handler guy you'd be in business.

I went a different route. The guy i buy bits from sells tomb king chassies pretty cheap and as long as i dont use the actual chaos charioteers models for the riders i can keep it pretty light. 6 chariots, 2 gorebeast, 4 regular, with all of the yoke and chains using bestigor bodies and spare bits lying around i was able to get all 6 chariots for $107 plus $6 in shipping. It should work with a little effort to chaos up the chariots.

Does anyone have any reccomendations for substitute mounts? The chassies are easy to get he has a handful more and the yoke and chains he has lots as no one wants that stuff.

Marauder horsemen horses are pretty cool- very armored and dynamic. Not sure how cheap the bits are, though.

Fenrisian wolves from the 40k Space Wolves range could be cool. You get quite a few in a box iirc.