My memory on this is a little vague, but I recall seeing some kind of “Behind the Music”-type show about “Married… with Children” where the writers/producers said they’d gotten the whole show cast but couldn’t find their Al Bundy. They’d seen “every guy in town” or something like that. Then one of them remembered seeing Ed O’Neill in a play in LA and thought it was one of the best stage performances he’d ever seen. So they sent him a script. As their story goes, he showed up to the audition with the character fully formed, and the second he walked in the door, they knew they’d found their Al.
It puts me in mind of Jim Varney. People who saw him onstage when he was young said he might (and should) have become one of the finest Shakespearean actors of his generation, given the chance. But then he developed the Ernest P. Worrell character and his career never quite got out from underneath it.
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