@tim.mcmanus:
I know you don't want to merge pfSense instances into one, but that's honestly the easiest way to do it. Then you can have WAN1, WAN2, LAN1, LAN2, and do the routing that way.
Thanks for the screenshot.
I tried again adding a vSwitch and interfaces to both boxes and still couldn't get the rules to pass packets between them. It should have worked but it didn't. I looked at the routing table and it looked like the rule was too far down in the table and never got triggered, which would explain why the packets went out to the internet.
In the end I mostly did as you suggested. I added the VMs that were attached to the second rounter into the first router so they can connect. Then I added an interface to the second router as wan2 on the first router. Then I added a rule to the first router to push traffic to the second router and out through WAN2. A little kludgy but it works. The DHCP is the only issue with the setup now, but I just used static IPs and it works ok. Not as isolated as previously but its working now.
Thx again for the help.