Vaughan was an apprentice with Rotherham United, later turning professional with Rotherham and making his league debut in the 1979–80 season.[2] He played 25 times in the league for Rotherham, scoring a blinding right footed volley in the memorable FA Cup first-round game vs York City during the 1980/1 season.
Vaughan's career highlights at Rotherham included a celebration of Rotherham's promotion to the Second Division at the close of the 1980–81 season, making 10 appearances, the same year, Vaughan captained the Rotherham side in a 2–1 win over rivals Sheffield Wednesday in the final of the Sheffield & Hallamshire County Cup.
He also made 10 appearances while on loan to Stockport County, before leaving to join then non-league Burton Albion. He subsequently joined Mossley, playing 85 times in the 1986–87 season before leaving to finish his career with Buxton FC .[3]
