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@fahrenheit
Thanks for the comments guys. I just had another look now and it's actually more like 5 turns I can get on and it would take 9 to get the end of the axle flush with the end of the nut. So I'm about 3-4mm short. Total nut height is 12mm, of which about 11mm are threaded.
I suppose I'll give using less spacers and squeezing frame a go. Not sure whether the tension that creates on the nuts, i.e. pushing them outwards, would help my cause though.
Jammy, def still interested in the custom axle though. Thanks for letting me know. Give me a shout if the other two candidates fall through.
Surely, there are quite a few people with this problem. Could consider getting a bulk of these done and flogging them... Hm...