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(written from a Production point of view)
Vaughn had recurring roles on such television series as Life Goes On (starring Bill Smitrovich and Ray Buktenica), Murder One (starring Daniel Benzali and John Fleck), 24, and as a reporter on ABC's series Commander in Chief. He also guest starred in the first regular episode and penultimate episode of China Beach, starring Robert Picardo, Megan Gallagher, Jeff Kober, and Concetta Tomei. Other television series on which he has guest-starred include Walker, Texas Ranger (with Noble Willingham and Bruce McGill), Picket Fences (with Ray Walston), and JAG (on which he guest-starred with the likes of Corbin Bernsen, Bill Bolender, Cliff DeYoung, Glenn Morshower, Terry O'Quinn, and Jack Shearer).
In 1989, he co-starred with Rene Auberjonois and Duncan Regehr in the television movie tale of Billy the Kid. In the 1990s, he appeared in two made-for-TV movies co-starring Christopher McDonald: 1995's The Tuskegee Airmen (with Tim Kelleher, Ed Lauter, and Janet MacLachlan) and 1997's Into the Air: Death of Everest.
Vaughn has appeared in a number of major feature films, including 1990's The Hunt for Red October (with Daniel Davis, Boris Lee Krutonog, and featuring Gates McFadden in a small role), 1995's Apollo 13 (with Max Grodénchik, David Andrews, Googy Gress, Clint Howard, and Andy Milder), and 1996's Courage Under Fire (with Tim Ransom, Bruce McGill, and Albert Hall). He was also in 1988's The Rescue, co-starring James Cromwell and Leon Russom. Vaughn like fellow TNG guest star Noble Willingham is a registered Republican and attempted a run for a seat on the California State Assembly. Vaughn won endorsement from fellow California Republican and high ranking Congressman Kevin McCarthy. Vaughn however was unsuccessful in his stump in the primary.