Career
A Birmingham City and Portsmouth trainee, Vaughan joined Walsall in February 2005 in a non-contract basis. He made his senior debuts while on loan at Willenhall Town, and subsequently moved to A.F.C. Telford United in the 2006 summer. On 11 May 2010 Vaughan joined Kidderminster Harriers.
He appeared in 157 league matches for Harriers which included getting in the 2012/13 conference team of the year alongside team mates Josh Gowling and Anthony Malbon, a season where Harriers finished 2nd in the league, before rejecting a new deal in May 2014.
On 19 May 2014 Vaughan signed a two-year deal with Football League Two side Cheltenham Town.