Cool idea. I concur about the churro probably not being the best axle material however. We have seen that you can tweak a churro just using holding together a chassis, and I would assume there would be a similar load on your axles. Also I second
this hex shaft from VexPro. We used some of it this year and it's held up real well.
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2016:
Team 5940 (Silicon Valley Regional Rookie All-Star and Quarterfinalist, Curie Quarterfinalist)
Volunteer: 2016 (Chezy Champs Field Reset, Capital City Classic FTA, MadTown ThrowDown FTA)