Thanks for replies. I'm confident about tailstock alignment. I think the method is wrong – the tailstock / chuck / slot drill assembly just isn't rigid enough to prevent the tail wagging the dog.
NDIY – thanks for the reminder about the knurling trick. I always forget about that! Unfortunately it wont work here because the 6mm shaft has to pass through a bearing during assembly.
I don't have a boring bar small enough, but the 'cheap and nasty' method Malcolm recommends sounds good – I think JasonB suggested essentially the same method as well. I'll give that a go.
Thanks to all for suggestions, Robin.