An Australia and Tonga international and Queensland State of Origin representative prop, he played for the Canterbury-Bankstown Bulldogs, Melbourne Storm, North Queensland Cowboys and the Newcastle Knights in the NRL, and the London Broncos, Huddersfield Giants and the Bradford Bulls in the Super League.

His junior club was Brothers in Bundaberg and he played rugby union for Nudgee College in Brisbane in 2002.

In 2006 Kaufusi was called up to the Australian tri-nations squad after Reni Maitua received an ankle injury in the first test against New Zealand.

On 25 June 2010, Kaufusi was released from his contract with the North Queensland Cowboys to join the Newcastle Knights for the rest of 2010 and a further two years.

On 18 August 2011, Kaufusi signed a 3-year deal with the London Broncos in the Super League after the 2012 Knights coach, Wayne Bennett, released him from his contract a year early.