By the way, I have seen exactly one barrel which was visibly straight when set up in the lathe. By visibly straight, I mean there was no apparent runout of the bore when the lathe was running. It is possible to see a couple thou of runout this way. This barrel was no perfectly straight but was very, very, close. After I dialed in the muzzle to cut and crown it, I cut off four inches and checked it again. TIR was .0004; so that bore was offset by 2 tenths at that point, Pretty damn straight. I have seen a few others which were very close but a lot more which were freakin' awful!
Generally, if the drill gets a poor start, it ain't gonna get any better. One maker I visited drilled consistently crooked barrels and employed a barrel straightening press to attempt to straighten them, There was a stack of blanks next to the press and I picked one up and had a look through it. When I asked to see one of the straightened ones, he seemed offended and told me that was straight. It was not even close. The bores on those barrels were corkscrews, and I don't now how you would straighten them.
When I was working in a hydraulics shop, I was tasked with making some cylinders which featured a rod which had a hole drilled up the center (a probe fit inside the rod and signaled the amount of extension). Two of these were 2 1/2 inch rods, 54 inches long, and needed a 9/16 hole 52 inches deep. I took two new drill bits and turned 3/4 inch of the shank to 3/8 inch. I then fitted a 1/2 inch extension, 28 inches long, to the bit and silver soldered it on. The bits and extensions were perfectly straight I set the rod up in the headstock, just like I would a barrel. I bored a hole 9/16 by 3/4 inch deep, the give the drill a good start, and started drilling. I could drill 1/2 inch before pulling out to clear the chip. I took about a half hour to drill 28 inches deep. Then, I flipped the rod around and drilled from the other end. When I broke through, I pushed past the meeting point and there was no apparent offset. The second rod didn't come out as well and there was about .005 of offset. I then welded a plug in one end, to make the holes the proper depth, fitted the pistons, and there they were.
Previous to this, we had always sent these rods to a shop which had a gun drilling machine. This time, he wasn't going to be able to guarantee quick delivery, so I decided to give it a shot. I did them all in house after that. This shows that a common twist drill can do pretty good work, especially if it gets a good start. It's just a lot of work! WH