Simple Axle

   / Simple Axle #11  
You mentioned a wood dowel didn't work, not surprising if you need any load capacity at all. I'd also skip aluminum, some alloys are fairly strong, but they will be much more expensive than steel and won't work as well.

If you don't want to deal with steel tubing and bushings as suggested, how about using a 5/8" steel rod and some angle or channel for the larger center portion. The rod could be U-bolted to the angle or channel at each end. No welding required, only need to drill two holes for each U-bolt and cotter pin.
 
   / Simple Axle #12  
You can buy axle stubs and hubs at tractor supply.
 

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