[jesset]

What is the best course to drill a 1/16" diameter 5" long offset hole into the length of a piece of 6061 aluminum hex bar?

I tried using an extra length aircraft drill bit, but it wobbles too much because of the small diameter of the bit. I was using a drill press, made a jig, and the bit broke from being too aggressive. The bit also wobbled the whole time. I am wondering if I could use a bit with 3" flute length and drill from either side. I have an old South Bend lathe and am wondering if it would be better do try this sort of thing on the lathe, rather than the drill press.

Is there any way to drill an off-center hole like this with a six-jaw chuck? If so, how would I do it?

Or is there some other way to drill this long of a hole that I may not be thinking of?

What is the best drill bit for doing this. I've read parabolic bits are best for cutting aluminum, but was wondering if any of you have done this and what bit I should buy?