For many fans of the long-running ITV soap Emmerdale, the character of Robert Sugden is synonymous with actor Ryan Hawley, who has played the role since 2014. However, Hawley was actually the fourth actor to portray the troubled son of Jack and Pat Sugden, and the man who first made the role famous has led a fascinating life since leaving the Dales.
The Original Robert Sugden's Emmerdale Tenure
Robert Sugden was born on-screen in 1986, with Richard Smith the first to play him as a baby. However, it was actor Karl Davies who truly defined the character for a generation of viewers. Davies took on the role in 2001 and played Robert until 2005, with a brief return in 2009 for his father Jack's funeral.
During his time in the soap, Davies was at the centre of some of Emmerdale's most explosive plots. These included a bitter and ongoing feud with his on-screen brother Andy, played by Kelvin Fletcher, and a controversial affair with Andy's wife, Katie, portrayed by Sammy Winward.
The storylines were so convincing that they sparked strong reactions from the audience. Davies once revealed to the Daily Record that he was even confronted by angry fans in public. "When I’m out and about girls will give me a scolding because of Robert’s cheating," he said in 2005, adding, "I was hit by a handbag a couple of years ago."
Turning Down a Return and Life After the Soap
When producers decided to bring Robert Sugden back to the village in 2014, their first choice was to ask Karl Davies to reprise the role. However, the actor declined the offer. Emmerdale producer Kate Oates confirmed this at the time, stating they had to "look elsewhere" after Davies expressed his desire to pursue other projects.
This decision paved the way for Ryan Hawley to step into the part, a move that has since become iconic. Davies later commented on the recast in 2016, telling SoapLife magazine he was often stopped by people telling him about the new Robert. He admitted he hadn't watched the show since leaving, but reflected fondly on his time there, calling Emmerdale his "drama school."
A Thriving Acting Career Beyond the Dales
Since departing Emmerdale almost two decades ago, Karl Davies has built an impressive and varied career in television. He has successfully avoided being typecast, landing roles in some of Britain's biggest dramas.
His notable credits include:
- Game of Thrones as Alton Lannister
- Happy Valley as Daryl Garrs
- Call the Midwife
- The Syndicate
- The Bay
Most recently, in September 2025, it was reported that Davies had been cast in the returning school drama Waterloo Road. He is set to play a character named Tony Walters in the sixteenth series, starring alongside Kym Marsh in what is promised to be an intense storyline.
While Ryan Hawley's portrayal is now definitive for many, Karl Davies's legacy as the original, controversial Robert Sugden remains a significant chapter in Emmerdale's history. His successful career post-soap demonstrates a clear path forged on his own terms, far away from the fictional Yorkshire village.
