Fans of Coronation Street know Sam Aston as the ever-familiar Chesney Brown, a character he has embodied since 2003. Recently, Sam lifted the curtain on what it’s truly like behind the scenes, sharing an amusing and heartfelt insight into his relationship with veteran co-star David Neilson, beloved for his portrayal of Roy Cropper.

Appearing on Kelvin Fletcher and Liz Marsland’s Off Script podcast, Sam couldn’t help but gush about David’s surprising off-screen personality. While Roy is often serious, socially awkward, and intensely reserved on screen, David is the complete opposite in real life — brimming with a dry, mischievous sense of humor that often causes unexpected hiccups during filming.

“He’s great, he’s really funny because he’s so different to Roy,” Sam explained warmly. “His humor is very dry. It’s actually hard to keep a straight face when you’re acting with him because he’ll deliberately do something silly when the cameras are rolling.” Sam described how David often sneaks in small, daft gestures just out of shot, purposefully trying to break his co-stars’ composure, which sometimes leads to uncontrollable laughter and extra takes.

Sam’s admiration for David goes deeper than just light-hearted banter. He reflected on their long-standing working relationship and how intertwined their characters’ lives have been over the years. For longtime Corrie viewers, it’s impossible to forget how vital Roy Cropper and his wife Hayley were in Chesney’s early life, especially during some of his most turbulent years.

“When Chesney was going through a rough patch at home, Roy and Hayley really stepped in. They were like surrogate parents,” Sam reminisced fondly. “Roy even took Chesney to karate lessons. We did all sorts together – it was brilliant.”

This bond was especially important after Chesney’s mother, Cilla Battersby (portrayed by Wendi Peters), abandoned him and his sister Fiz (played by Jennie McAlpine) to pursue a new life in Las Vegas. Left to fend for themselves, the two siblings found stability through the kindness of people like Roy and Hayley, solidifying the Cropper’s place in Chesney’s life and the viewers’ hearts.

Today, Chesney has carved out his own version of family life on the cobbles. He is now married to Gemma Winter, and together they manage the chaos of raising five children, including one from a previous relationship. Sam’s portrayal of Chesney’s journey from a troubled child to a devoted father mirrors his own growth within the Coronation Street family — a journey that’s been heavily shaped by David Neilson’s steady influence, both on and off screen.

The affection Sam feels for David is echoed by millions of Coronation Street fans, who continue to hold Roy Cropper as one of the soap’s most beloved characters. Over the years, Roy has been at the center of some of the most moving storylines in the show’s history. A standout moment remains the heartbreaking arc surrounding the death of Roy’s wife Hayley, who succumbed to pancreatic cancer in 2014. The emotionally charged scenes were widely praised and showcased David’s incredible range as an actor.

More recently, Roy found himself embroiled in a gripping murder mystery plot involving the death of Lauren Bolton (played by Cait Fitton). Wrongly accused and imprisoned for Lauren’s murder, Roy’s name was eventually cleared, but not before viewers were taken on an emotional rollercoaster that kept them glued to their screens. Through it all, David Neilson’s nuanced performance reminded audiences why Roy Cropper remains a cornerstone of Coronation Street.

Despite the heavy material his character often faces, David’s off-screen antics reveal a lighter side to the seasoned actor, making him not only a mentor but a source of genuine joy for younger cast members like Sam Aston.

As Sam’s reflections show, the magic of Coronation Street doesn’t just happen in front of the camera. It’s forged in the real bonds between its cast, the shared laughter, the unbreakable friendships, and the countless memories made between takes — elements that have kept the soap running strong for over six decades.

With stars like David Neilson bringing both professionalism and a playful spirit to the set, it’s no wonder that Coronation Street continues to be a beloved staple in British television, generation after generation.