Born in Liverpool, Vaughan was signed by Chester in January 2006 from Tranmere Rovers, where he made more than 50 reserve team appearances.

His first-team debut came when he replaced his brother in the closing stages of Chester's 4–4 draw in the EFL Trophy at Chesterfield on 29 November 2006.

After a successful loan spell at Droylsden, who he helped win the Conference North title, Vaughan returned to Chester and was a regular in the closing matches of the 2006–07.

Vaughan was given squad number 22 for 2007–08 and commanded a regular spot as first-choice right back for the next two seasons the English Football League.

This biographical article related to association football in England, about a defender born in the 1980s, is a stub.