Born in Chesaning, Michigan, Roger Callard started building his body at the age of five. He attended Michigan State University and then participated in bodybuilding championships. He won the 1977 title of Mr. America of the International Federation of Bodybuilders middleweight. At this time he was training with Arnold Schwarzenegger at the Gold's Gym and was also seen in the two bodybuilding films Mr. Universe and Pumping Iron.

Callard soon retired from professional bodybuilding and began an acting career. First, he had guest appearances in various television series and in the feature film Sextette with Timothy Dalton and Tony Curtis. In the 1980s, he often collaborated with Schwarzenegger; he worked as a stuntman on The Phantom Commando and The Total Remembrance - Total Recall and as a cast member in Twins - Twins and Red Heat. In 1989, in Weird Al Yankovic's comedy film UHF - Radio with Limited Hope, he parodied Schwarzenegger's role as Conan. He had another film roles in Walter Hills Western Geronimo - A legend, after which he played mainly in television productions.