Vaughan started his playing career at his local professional side Newport County making 224 appearances and scoring 32 goals for the club.
After leaving Caerleon Comprehensive School in 1975 he made his Football league debut against Rochdale as a left back at the age of 17 by manager Jimmy Scoular.
In 1980, he played a pivotal role in helping Newport County to double success, by achieving promotion from the old Division 4 and winning the Welsh Cup against Shrewsbury Town (5–1 on aggregate).
The following year he made his full international debut in a 1–1 draw against Telê Santana's Brazil at Ninian Park on 12 June 1983.
He went on to play against Norway, Romania, Bulgaria, Yugoslavia, Northern Ireland, Israel and Spain under the leadership of manager Mike England.
He stayed at Wolves for more than eight years coaching the U15s & U16s on a part-time basis, working alongside Welsh former International manager Mike Smith and Steve Wheatley.
During this period Vaughan coached a number of players who went on to become professional footballers – most notably Lee Naylor, Joleon Lescott, John Melligan, Scot Brown, Leon Clarke and Michael Townsend.
From 2003 to 2010 Vaughan was invited by former manager Len Ashurst to coach at the Premier League exit trial, for under 18/19 scholars who were released by their clubs where he work for four years.
In February 2018 Vaughan met Misdella Mechela Perez a Cuban lady and after a three-year courtship, they decided to get married on Friday 1 July 2021 in Richmond, Houston, Texas.
Vaughan accepted the position in March and moved house at the end of the Spring Season 2022 from Tomball to Mission Bend, in Houston, Texas.