While working at a job in the sound effects department of NBC Radio, he did a nightclub act and appeared and won on the Arthur Godfrey's Talent Scouts radio show. While appearing on Broadway in Stalag 17, he got his break into television by getting the role of Corporal Steve Henshaw[2] on the popular The Phil Silvers Show program.[3] "I think the camaraderie of all those guys made it such a pleasant way to work. They were so relaxed."[3]
During this period, in addition to his role on The Phil Silvers Show, Melvin was often cast in slightly loud, occasionally abrasive, but generally friendly second banana roles. Melvin was also adept at "tough guy" roles; in an example of his range as an actor, one episode of The Phil Silvers Show featured Melvin doing an impersonation of Humphrey Bogart.
In the 1960s, Melvin worked extensively at CBS for Sheldon Leonard and Aaron Ruben. He made eight guest appearances on The Andy Griffith Show in eight different roles, usually as heavies, and a further appearance as yet another character on its successor show, Mayberry, R.F.D.. He played Staff Sgt. Charlie Hacker, who was Sgt. Vince Carter's rival, for four seasons on the Andy Griffith Show spin-off Gomer Pyle, USMC. He also made eight appearances on The Dick Van Dyke Show.
Melvin is remembered for supporting roles on two popular 1970s sitcoms. He played Sam Franklin, the owner of a local butcher shop and boyfriend of the Brady's housekeeper Alice (played by Ann B. Davis) on The Brady Bunch, and Barney Hefner, Archie Bunker's neighbor and friend on All in the Family. In other contributions to 1970s pop culture, he worked as a voice artist (under the name "Al Melvin"). He provided several characters' voices for the TV show H.R. Pufnstuf and the voice of Prince Thun of the Lion Men on The New Adventures of Flash Gordon. He also provided the voice of Rocky Maninoff for Tennessee Tuxedo in the episode "Mixed-up Mechanics" in 1963.
He also worked extensively in television commercials, including fifteen years as Al the Plumber on Liquid-Plumr drain opener commercials.[4]
In the early 1980s, Melvin appeared as a regular in Archie Bunker's Place, in which he reprised the now more important role of Barney Hefner. After the series ended in 1983, Melvin's work was exclusively devoted to cartoon voice-overs. His voice acting career continued until 1994, with Scooby-Doo! in Arabian Nights being his final voice work (again as Magilla Gorilla) before retiring.
Clarence 'Doc' Malloy in Jailbreak; Escaped Prisoner in Andy's Vacation; Clyde Plaunt in Howard's Main Event; Hotel Detective Bardoli in Andy & Barney in the Big City; Myrt's Accomplice Jake in Barney's First Car; Recruiting Sergeant in Ernest T. Bass Joins the Army; Farmer Neal in Lawman Barney; Fred Plummer in Barney's Uniform